Fuel Tank Replacement (Pickup)

REMOVAL PROCEDURE

1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Disconnect the fuel fill hose from the fuel tank.
4. Remove the fuel system cooler (1).
5. Cap the fuel pipes in order to prevent possible fuel system contamination.
6. Disconnect the fuel sender electrical connector.

7. Remove the fuel tank shield.

8. With the aid of an assistant, support the fuel tank.
9. Remove the fuel tank strap attaching bolts.
10. Remove the fuel tank straps.
11. Remove the fuel tank.
12. Place the fuel tank in a suitable work area.

13. Remove the fuel feed pipe and the fuel return pipe from the fuel sender (1) and the retaining clips (3).
14. Remove the fuel sender assembly from the fuel tank.

INSTALLATION PROCEDURE

1. Install the fuel sender assembly to the fuel tank.
2. Connect the fuel feed pipe and the fuel return pipe to the fuel sender (1) and the retaining clips (3).

3. With the aid of an assistant, position and support the fuel tank.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the fuel tank straps.

Tighten
Tighten the fuel tank strap attaching bolts to 40 N.m (30 lb ft).

5. Install the fuel tank shield to the fuel tank clips.

6. Install the fuel tank shield to frame bolts.

Tighten
Tighten the bolts to 18 N.m (13 lb ft).

7. Connect the fuel sender harness connector.

8. Remove the caps from the fuel pipes.
9. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes.
10. Install the fuel system cooler (1).
11. Connect the fuel fill pipe ground strap.

Tighten
Tighten the fuel fill pipe ground strap bolt to 9 N.m (80 lb in).

12. Connect the fuel fill pipe to the fuel tank.
13. Lower the vehicle.
14. Fill the fuel tank.
15. Install the fuel filler cap.
16. Connect the negative battery cable.
17. Prime the fuel system. Refer to Fuel Feed and Fuel Return Pipe Purge Procedure.
18. Start the engine and test for fuel leaks.