Rear - Cab/Chassis

FUEL TANK REPLACEMENT (CAB/CHASSIS - REAR)

REMOVAL PROCEDURE




1. Loosen the fuel fill and vent hose clamps (1, 2) at the tank.
2. Remove the fuel fill and vent hose from the tank.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.




4. Disconnect the sending unit electrical connector.




5. Disconnect the fuel feed and return lines from the sending unit.
6. Raise and suitably support the vehicle. Refer to Vehicle Lifting.




7. If equipped, remove the fuel tank shield bolts.
8. If equipped, remove the fuel tank shield.




9. Remove the fuel tank strap bolts.

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

10. Remove the fuel tank straps.
11. Lower the fuel tank.
12. With the aid of an assistant, place the fuel tank in a suitable work area.
13. Cap the fuel lines in order to prevent possible fuel system contamination.
14. 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 lines.
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. If equipped, install the fuel tank cover.
9. If equipped, install the fuel tank cover bolts.

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

10. Lower the vehicle.




11. Connect the fuel feed and return lines to the sending unit.




12. Connect the sending unit electrical connector.




13. Install the fuel fill and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps (1, 2) at the tank.

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

15. Fill the fuel tank.
16. Install the fuel fill cap.
17. Install the negative battery cable.
18. Using a scan tool, command the fuel transfer pump on.
19. Prime the fuel system. Refer to Fuel System Priming.
20. Start the engine. If the engine stalls, repeat the above step.
21. Once the engine starts, inspect for fuel leaks.