Front - Cab/Chassis

Fuel Tank Replacement (Cab/Chassis - Front)







REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
Fuel Pressure Release
2. Disconnect the fuel feed and pressure balance rear pipes, if required.







3. Loosen the fuel fill and vent hose clamps at the tank.
4. Remove the fuel fill pipe and vent hose from the tank.
5. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
Procedures







6. Disconnect the fuel sending unit and pressure sensor electrical connectors (1).







7. Disconnect the fuel feed/return pipes from the fuel tank pipes.
8. Raise and suitably support the vehicle. Refer to Vehicle Lifting.







9. Remove the fuel tank shield bolts.
10. Remove the fuel tank shield.
11. Place a suitable adjustable jack under the fuel tank.







12. Remove the fuel tank strap bolts.

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions Vehicle Damage Warnings.

13. Remove the fuel tank straps (1).
14. Lower the fuel tank.
15. With the aid of an assistant, place the fuel tank in a suitable work area.
16. Cap the fuel and EVAP pipes in order to prevent possible fuel/EVAP system contamination.
17. If replacing the fuel tank, remove the sending unit.







INSTALLATION PROCEDURE
1. If the fuel tank was replaced, install the sending unit.
2. Remove the caps from the fuel and EVAP pipes.
3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank.
5. Install the fuel tank straps (1).

NOTE: Refer to Fastener Notice in Service Precautions Fastener Notice.

6. Install the fuel tank strap bolts.

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







7. Remove the jack from under the fuel tank.
8. Install the fuel tank shield.
9. Install the fuel tank shield bolts.

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

10. Lower the vehicle.







11. Connect the fuel feed/return pipes to the fuel tank pipes.







12. Connect the fuel sending unit and pressure sensor electrical connectors (1).







13. Install the fuel fill pipe and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps at the tank.

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







15. Connect the fuel feed and pressure balance rear pipes, if required.
16. Install the fuel fill cap.
17. Connect the negative battery cable.
18. Use the following procedure in order to inspect for leaks:
18.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
18.2. Turn the ignition OFF for 10 seconds.
18.3. Turn the ignition ON, with the engine OFF.
18.4. Inspect for fuel leaks.