Fuel Tank Replacement

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise and support the vehicle, high enough to access the top of the fuel tank through the wheelhouse liner. Refer to Vehicle Lifting.
4. Remove the left pickup box wheelhouse liner.




5. Disconnect the fuel filler hose (4) from the fuel tank (3).
6. Disconnect the evaporative emission (EVAP) hose (2) from the filler vent tube (1).




7. Disconnect the following electrical connectors from the fuel tank:
- The fuel tank pressure sensor (2)
- The fuel tank module (3)
8. Disengage the fuel wiring harness from the retainer (5) on the fuel tank.
9. Raise the vehicle fully.




10. Disconnect the middle of the EVAP vapor pipe (1, 3) located between the fuel tank and the EVAP canister.




11. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in order to disconnect the following from the chassis bundle (2, 3):
- The fuel return hose (1)
- The fuel filter (4)

NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.




12. Remove the upper fuel tank strap bolt.
13. Remove the upper fuel tank strap.
14. Support the fuel tank.




15. Remove the lower fuel tank strap bolt.
16. Remove the lower fuel tank strap.
17. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
18. Place the fuel tank in a suitable work area.
19. If the fuel tank is not being replaced, go to the Installation Procedure.

DISASSEMBLY PROCEDURE
1. Remove the fuel filter.




2. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in order to disconnect the following from the fuel tank module (2):
- The EVAP pipe (5)
- The fuel return pipe (6)
- The fuel feed pipe (7)
3. Disconnect the EVAP pipes (3, 5) from the vent valve (4).
4. Disengage the following from the retaining clips (1):
- The fuel return pipe (6)
- The fuel feed pipe (7)
5. Disengage the EVAP pipe (5) from the retaining features molded into the fuel tank.
6. Remove the fuel tank module from the fuel tank.

ASSEMBLY PROCEDURE
1. Install the fuel tank module into the fuel tank.




2. Secure the EVAP pipe (5) to the retaining features molded into the fuel tank.
3. Secure the following to the retaining clips (1):
- The fuel return pipe (6)
- The fuel feed pipe (7)
4. Connect the EVAP pipes (3, 5) to the vent valve (4).
5. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in order to connect the following to the fuel tank module (2):
- The EVAP pipe (5)
- The fuel return pipe (6)
- The fuel feed pipe (7)
6. Install the fuel filter.

INSTALLATION PROCEDURE




1. With the aid of an assistant, carefully position and support the fuel tank to the vehicle.
2. Install the lower fuel tank strap.
3. Install the lower fuel tank strap bolt. Do not tighten at this time.




4. Install the upper fuel tank strap.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Install the upper fuel tank strap bolt.

Tighten
Tighten the fuel tank strap bolts to 32 N.m (24 lb ft).




6. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in order to connect the following to the chassis bundle (2, 3):
- The fuel return hose (1)
- The fuel filter (4)




7. Connect the middle of the EVAP vapor pipe (1, 3) located between the fuel tank and the EVAP canister.
8. Lower the vehicle only enough to gain access the fuel tank through the wheelhouse.




9. Connect the following electrical connectors to the fuel tank:
- The fuel tank pressure sensor (2)
- The fuel tank module (3)
10. Secure the fuel tank wiring harness to the retainer (5) on the fuel tank.




11. Connect the fuel filler hose (4) to the fuel tank (3).

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

12. Connect the EVAP hose (2) to the filler vent tube (1).
13. Install the left pickup box wheelhouse liner.
14. Lower the vehicle.
15. Refill the fuel tank.
16. Install the fuel filler cap.
17. Inspect for leaks.
17.1. Turn ON the ignition, with the engine OFF for 10 seconds.
17.2. Turn OFF the ignition for 10 seconds.
17.3. Turn ON the ignition, with the engine OFF.
17.4. Inspect for fuel leaks.