Fuel Tank Replacement (Pickup)

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup).
3. Remove the fuel fill pipe housing to body screws (1) and retainer (2).




4. Remove the fuel fill pipe housing to fuel fill pipe bolts.
5. Remove the fuel fill pipe housing.
6. Remove the vent hose from the clip on the fuel fill pipe.
7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.




8. Remove the fuel fill pipe ground strap bolt.
9. Loosen the fuel fill hose clamp at the tank.
10. Remove the fuel fill pipe/hose.
11. Remove the evaporative emission (EVAP) canister.




12. Disconnect the fuel return and feed pipes from the fuel tank pipes.
13. Disconnect the EVAP pipe from the fuel tank EVAP pipe.
14. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.




15. Remove the fuel tank shield, if equipped.




16. Support the fuel tank with a suitable jack.
17. Remove the fuel tank strap bolts.
18. Remove the fuel tank straps.
19. With the aid of an assistant, lower the fuel tank, until the electrical connectors are accessible.




20. Disconnect the fuel sender and fuel pressure sensor electrical connectors.
21. Place the fuel tank in a suitable work area.




22. Disconnect the fuel feed pipe (4) and fuel return pipe (5) from the fuel sender (2) and the retaining clips (6).
23. Disconnect the EVAP pipe (1) from the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
24. Remove the fuel sender, if required.

INSTALLATION PROCEDURE




1. Install the fuel sender, if required.
2. Connect the EVAP pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
3. Connect the fuel feed pipe (4) and the fuel return pipe (5) to the fuel sender and the retaining clips (6).




4. With the aid of an assistant, place the fuel tank on a suitable jack.
5. With the aid of an assistant, raise the fuel tank.
6. Connect the fuel sender and fuel pressure sensor electrical connectors.




7. Install the fuel tank.
8. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

9. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N.m (30 lb ft).

10. Remove the jack.




11. Install the fuel tank shield, if equipped.




12. Remove the caps from the fuel and EVAP pipes.
13. Connect the EVAP pipe to the fuel tank EVAP pipe.
14. Connect the fuel return and feed pipes to the fuel tank pipes.
15. Install the EVAP canister.




16. Install the fuel fill pipe/hose.
17. Tighten the fuel fill hose clamp at the tank.

Tighten
Tighten the clamp to 2.5 N.m (22 lb in).

18. Install the fuel fill pipe ground strap bolt.

Tighten
Tighten the bolt to 9 N.m (80 lb in).

19. Lower the vehicle.




20. Install the vent hose to the clip on the fuel fill pipe.
21. Install the fuel fill pipe housing.
22. Install the fuel fill pipe housing to fuel fill pipe bolts.

Tighten
Tighten the bolts to 2.3 N.m (20 lb in).




23. Install the fuel fill pipe housing to body screws (1) and retainer (1).

Tighten
Tighten the screws to 2.3 N.m (20 lb in).

24. Refill the fuel tank.
25. Install the fuel fill cap.
26. Use the following procedure in order to inspect for leaks:
26.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
26.2. Turn OFF the ignition for 10 seconds.
26.3. Turn ON the ignition, with the engine OFF.
26.4. Inspect for fuel leaks.