Fuel Tank Replacement (Pickup)

FUEL TANK REPLACEMENT (PICKUP)

REMOVAL PROCEDURE




1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
3. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
4. Loosen the clamp at the fuel inlet neck.
5. Remove the fuel fill hose from the inlet neck.
6. Remove the fuel system cooler.




7. Remove the fuel tank shield bolts, if equipped.
8. Remove the fuel tank shield, if equipped.




9. Disconnect the fuel feed and return pipes from the fuel tank pipes.
10. Cap the fuel pipes in order to prevent possible fuel system contamination.
11. Place a suitable adjustable jack under the fuel tank.




12. Remove the fuel tank strap bolts.

NOTE: Refer to Fuel Tank Strap Fastener Notice in Service Precautions.

13. Remove the fuel tank straps.
14. Remove the fuel tank.
15. Lower the fuel tank until the electrical connector is accessible.
16. Disconnect the sending unit electrical connector.
17. With the aid of an assistant, place the fuel tank in a suitable work area.
18. If necessary, loosen the fuel inlet hose clamp at the tank.
19. If necessary, remove the fuel inlet hose from the tank.




20. Disconnect and remove the fuel feed and return pipes from the sending unit (1) and retaining clips (3).
21. If replacing the fuel tank, remove the sending unit.

INSTALLATION PROCEDURE




1. If the fuel tank was replaced, install the sending unit.
2. Install and connect the fuel feed and return pipes to the sending unit (1) and retaining clips (3).




3. If necessary, install the fuel inlet hose to the tank.

NOTE: Refer to Fastener Notice in Service Precautions.

4. If necessary, tighten the fuel inlet hose clamp at the tank.

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

5. With the aid of an assistant, place the fuel tank on the jack.
6. Raise the fuel tank until the electrical connector is accessible.
7. Connect the sending unit electrical connector.
8. Install the fuel tank.
9. Install the fuel tank straps.
10. Install the fuel tank strap bolts.

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

11. Remove the jack from under the fuel tank.




12. Remove the caps from the fuel pipes.
13. Connect the fuel feed and return pipes from the fuel tank pipes.




14. Install the fuel tank shield, if equipped.
15. Install the fuel tank shield bolts, if equipped.

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

16. Install the fuel system cooler.




17. Install the fuel fill hose to the inlet neck.
18. Tighten the clamp at the fuel inlet neck.

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

19. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
20. Lower the vehicle.
21. Fill the fuel tank.
22. Install the fuel fill cap.
23. Connect the negative battery cable.
24. Prime the fuel system.
25. Start the engine and test for fuel leaks.