Fuel Tank Replacement (Cab/Chassis - Rear)

Fuel Tank Replacement (Cab/Chassis - Rear)

Removal Procedure




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (CH-48027) (Service and Repair)Fuel Pressure Relief (Without CH-48027) (Service and Repair).
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
3. Drain the fuel tank. Refer to Fuel Tank Draining (Procedures).
4. Remove the fuel tank shield bolts (1) and the fuel tank shield (2).




5. Loosen the fuel fill hose clamp (1).




6. Support the fuel tank with a suitable jack.
7. Remove the fuel tank strap fastener (1).




8. Lower the tank enough to access the fuel pump module.
9. Disconnect the electrical connector (1) and the evaporative emissions lines and the fuel lines (2). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) and Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service)
10. Lower the fuel tank.
11. If replacing the fuel tank, remove the fuel pump module from the fuel tank. Refer to Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank))Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank))Fuel Tank Fuel Pump Module Replacement (15 Reg/Ext/Crew Cab w/34 Gal Tank) (Fuel Tank Fuel Pump Module Replacement (15 Reg/Ext/Crew Cab w/34 Gal Tank))Fuel Tank Fuel Pump Module Replacement (25/35 Series) (Fuel Tank Fuel Pump Module Replacement (25/35 Series)).
12. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

Installation Procedure




1. If removed, install the fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank))Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank))Fuel Tank Fuel Pump Module Replacement (15 Reg/Ext/Crew Cab w/34 Gal Tank) (Fuel Tank Fuel Pump Module Replacement (15 Reg/Ext/Crew Cab w/34 Gal Tank))Fuel Tank Fuel Pump Module Replacement (25/35 Series) (Fuel Tank Fuel Pump Module Replacement (25/35 Series)).
2. Partially raise the fuel tank enough to access the fuel pump module.
3. Connect the electrical connector (1) and fuel and evaporative emission lines. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) and Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service)





Caution: Refer to Fastener Caution (Fastener Caution).

4. Support the fuel tank with a suitable jack.
5. Install the fuel tank strap fastener (1) and tighten to 40 Nm (30 lb ft).




6. Tighten the fuel fill hose clamp (1) to 4 Nm (35 lb in).




7. Install the fuel tank shield (2) and tighten the fuel tank shield bolts (1) to 18 Nm (21 lb ft).
8. Refill the fuel tank.
9. Install the fuel filler cap.
10. Use the following procedure in order to inspect for leaks:

1. Turn ON the ignition, with the engine OFF, for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.