Fuel Tank Replacement (1500 Crew Cab)

FUEL TANK REPLACEMENT (1500 CREW CAB)

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. Remove the fuel tank fill pipe.
4. Remove the fuel tank shield bolts and shield, if necessary.




5. Remove the evaporative emission (EVAP) canister.




6. Disconnect the fuel feed line from the tank.
7. Cap the fuel and EVAP lines in order to prevent possible system contamination.
8. Place an adjustable jack under the fuel tank.
9. Remove the fuel tank strap bolts.
10. Remove the fuel tank straps.




11. Remove the harness clip from the frame.
12. Lower the fuel tank under the electrical connectors are accessible.
13. Disconnect the fuel tank pressure sensor (1) electrical connector.
14. Disconnect the fuel tank sending unit (2) electrical connector, perform the following:
1. Disengage the gray retainer.
2. Push down the black clip.
3. Disconnect the connector.
15. Completely lower the fuel tank.
16. With the aid of an assistant, place the fuel tank in a suitable work area.
17. If necessary, remove the sending unit.

INSTALLATION PROCEDURE




1. If necessary, install the sending unit.
2. With the aid of an assistant, place the fuel tank on a adjustable jack.
3. Raise the fuel tank until the electrical connections can be made.
4. Connect the fuel tank sending unit (2) electrical connector. Engage the gray retainer.
5. Connect the fuel tank pressure sensor (1) electrical connector.
6. Completely raise the fuel tank.
7. Install the harness clip to the frame.




8. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

9. Install the fuel tank strap bolts.

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

10. Remove the adjustable jack from under the fuel tank.
11. Remove the caps from the fuel and EVAP lines.
12. Connect the fuel feed line at the tank.




13. Install the EVAP canister.




14. Install the fuel tank shield and bolts, if necessary.

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

15. Install the fuel tank fill pipe.
16. Refill the fuel tank.
17. Install the fuel cap.
18. Connect the negative battery cable.
19. Perform the following procedure 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.