Fuel Tank Replacement

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.

NOTE: The pickup truck fuel tiller pipe contains screens. In order to prevent damage to the screens, do not drain the fuel through the fuel tank tiller pipe.

2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

3. Raise the vehicle and suitably support.
4. Remove the fuel tank shield (1).
5. With aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps (2).




6. Remove the fuel sender electrical connector.
7. Remove the fuel tank pressure (FTP) sensor electrical connector.




8. Remove the hoses from the fuel sender.
9. Remove the filler, vent and vapor pipes.
10. Remove the fuel tank (2) from vehicle.
11. Remove the sound insulators (1).

INSTALLATION PROCEDURE

IMPORTANT: Inspect all connectors for dirt and burrs.

Clean or replace components/assemblies as required. Fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.




1. Install the sound insulators (1).
2. With the aid of an assistant install the fuel tank (2) to the body.

CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

3. Install the hoses to filler, vent and vapor pipes.




4. Install the fuel tank pressure sensor electrical connector.
5. Install the fuel tank sender electrical connector.

NOTE: Refer to Fastener Notice in Service Precautions.




6. Install the fuel tank retaining straps (2).

Tighten
Tighten the bolts to 45 N.m (33 lb ft).

7. Install the fuel tank shield (1).
8. Lower the vehicle.
9. Refill the fuel tank.
10. Reconnect the negative battery cable.
11. Inspect for fuel leaks through the following steps:
11.1. Turn ON the ignition for two seconds.
11.2. Turn OFF the ignition for ten seconds.
11.3. Turn ON the ignition.
11.4. Check for fuel leaks.