Fuel Tank Replacement

FUEL TANK REPLACEMENT (PICKUP)

REMOVAL PROCEDURE




1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Remove the fuel tank filler housing to body screws (1), and retainer (2).




3. Remove the fuel tank filler housing to fuel tank fill pipe screws.
4. Remove the fuel tank filler housing.




5. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
6. Raise and suitably support the vehicle. Refer to Vehicle Lifting.




7. Remove the fuel tank ground strap bolt (1).
8. Reposition the fuel tank ground strap (3).




9. Loosen the fill pipe vent hose clamp (1) at the fuel tank.
10. Remove the fill pipe vent hose from the fuel tank.
11. Remove the fill pipe.
12. Remove the fuel system cooler.




13. If equipped, remove the fuel tank shield bolts.
14. If equipped, remove the fuel tank shield.




15. Disconnect the fuel feed and return lines.
16. Cap the fuel lines in order to prevent possible fuel system contamination.
17. Place a suitable adjustable jack under the fuel tank.




18. Remove the fuel tank strap bolts.

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

19. Remove the fuel tank straps.
20. Lower the fuel tank until the sending unit electrical connector is accessible.
21. Disconnect the sending unit electrical connector.
22. Completely lower the fuel tank.
23. With the aid of an assistant, place the fuel tank in a suitable work area.




24. If necessary, disconnect and remove the fuel feed (1) and return (2) lines from the sending unit and retaining clips.
25. 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 (1) and return (2) lines to the sending unit and retaining clips.




3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank until the sending unit electrical connection can be made.
5. Connect the sending unit electrical connector.
6. Install the fuel tank.
7. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

8. Install the fuel tank strap bolts.

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

9. Remove the jack from under the fuel tank.




10. Remove the caps from the fuel lines.
11. Connect the fuel feed and return lines to the fuel tank.




12. If necessary, install the fuel tank shield.
13. If necessary, install the fuel tank shield bolts.

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

14. Install the fuel system cooler.




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

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

17. Tighten the fuel tank vent hose clamp (1) at the fuel tank.

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




18. Position the fuel tank ground strap (3).
19. Install the fuel tank ground strap bolt (1).

Tighten the bolt to 9 N.m (80 lb in).




20. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
21. Lower the vehicle.




22. Install the fuel tank filler housing.
23. Install the fuel tank filler housing to fuel tank fill pipe screws.

Tighten the screws to 2.3 N.m (20 lb in).




24. Install the fuel tank filler housing to body screws (1), and retainer (2).

Tighten the screws to 2.3 N.m (20 lb in).

25. Fill the fuel tank.
26. Install the fuel fill cap.
27. Connect the negative battery cable.
28. Prime the fuel system. Refer to Fuel System Priming.
29. Start the engine. If the engine stalls, repeat the above step.
30. Once the engine starts, inspect for fuel leaks.