Front - Cab/Chassis

FUEL TANK REPLACEMENT (CAB/CHASSIS - FRONT)

REMOVAL PROCEDURE

IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding area prior to disconnecting the lines in order to avoid possible system contamination.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. If equipped with a rear auxiliary tank, disconnect the fuel feed and EVAP quick connect fittings.
3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.




4. Loosen the fuel fill pipe clamp (2) at the tank.
5. Loosen the vent pipe clamp (1) at the tank.
6. Remove the fuel fill pipe and vent pipe from the tank.
7. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.




8. Disconnect the fuel pressure sensor electrical connector (1).
9. Disconnect the fuel sending unit electrical connector (1), perform the following:
1. Disengage the gray retainer.
2. Push down the black clip.
3. Disconnect the connector.
10. Remove the canister vent solenoid (CVS) line from the fuel tank clips.




11. Disconnect the fuel feed and EVAP quick connect fittings from the sending unit.
12. Raise and suitably support the vehicle. Refer to Vehicle Lifting.




13. Remove the fuel tank shield bolts.
14. Remove the fuel tank shield.
15. Place a suitable adjustable jack under the fuel tank.




16. Remove the fuel tank strap bolts.
17. Remove the fuel tank straps.
18. Lower the fuel tank.
19. With the aid of an assistant, place the fuel tank in a suitable work area.
20. Cap the fuel and EVAP pipes in order to prevent possible system contamination.
21. If necessary, remove the sending unit.

INSTALLATION PROCEDURE




1. If necessary, 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.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the fuel tank strap bolts.

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

10. Lower the vehicle.




11. Connect the fuel feed and EVAP quick connect fittings to the sending unit.




12. Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
13. Install the CVS line to the fuel tank clips.




14. Install the fuel fill pipe and vent pipe to the tank.
15. Tighten the vent pipe clamp (1) at the tank.
16. Tighten the fuel fill pipe clamp (2) at the tank.

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




17. Remove the caps from the fuel feed and EVAP pipes.
18. If equipped with a rear auxiliary tank, connect the fuel feed and EVAP quick connect fittings.
19. Refill the fuel tank.
20. Install the fuel fill cap.
21. Connect the negative battery cable.
22. Perform the following steps in order to inspect for leaks.
1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.