Fuel Tank Replacement (Pickup)

FUEL TANK REPLACEMENT (PICKUP)

REMOVAL PROCEDURE

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




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Drain the fuel tank. Refer to Fuel Tank Draining (4.8L, 5.3L, and 6.0L Engine) Fuel Tank Draining (5.3L (L59) Engine).
3. Remove the fuel tank fill pipe.
4. Remove the EVAP canister vent solenoid.
5. Remove the fuel tank shield bolts, if equipped.
6. Remove the fuel tank shield, if equipped.




7. Disconnect the fuel feed and EVAP lines.
8. Cap the fuel and EVAP lines in order to prevent possible system contamination.




9. Place a suitable adjustable jack under the fuel tank.
10. Remove the fuel tank strap bolts.
11. Remove the fuel tank straps.
12. Lower the fuel tank half way.When lowering the tank, ensure that the fill neck on the tank does not get hung up on the harness.
13. Disconnect the electrical harness clip at the frame crossmember.
14. Lower the fuel tank until the electrical connections are accessible.




15. Disconnect the fuel pressure sensor electrical connector.
16. Disconnect the fuel sending unit electrical connector, perform the following:
1. Disengage the gray retainer.
2. Push down the black clip.
3. Disconnect the connector.
17. Completely lower the fuel tank.
18. With the aid of an assistant, place the fuel tank in a suitable work area.




19. If necessary, disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
20. If necessary, disconnect and remove the EVAP purge line (2) from the retaining clips.
21. If necessary, disconnect and remove the EVAP fuel level vent valve (FLVV) line from the FLVV, sending unit, and retaining clips.
22. If necessary, remove the sending unit.

INSTALLATION PROCEDURE




1. If necessary, install the sending unit.
2. If necessary, install and connect the EVAP FLVV line to the FLVV, sending unit, and retaining clips.
3. If necessary, install and connect the EVAP purge line (2) to the retaining clips.
4. If necessary, install and connect the fuel feed line (1) to the sending unit and retaining clips.




5. With the aid of an assistant, place the fuel tank onto the adjustable jack.
6. Raise the fuel tank until the electrical connections can be made.
7. Connect the fuel sending unit and pressure sensor electrical connectors.
8. Completely raise the fuel tank.When raising the tank, ensure that the fill neck on the tank goes over the harness.




9. Install the fuel tank straps.

NOTE: Refer to Fastener Notice.

10. Install the fuel tank strap bolts.

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

11. Remove the adjustable jack from under the fuel tank.




12. Remove the caps from the fuel and EVAP lines.
13. Connect the fuel feed and EVAP lines.




14. If necessary, install the fuel tank shield.
15. If necessary, install the fuel tank shield bolts.

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

16. Install the EVAP canister vent solenoid.
17. Install the fuel tank fill pipe.
18. Refill the fuel tank.
19. Install the fuel cap.
20. Connect the negative battery cable.
21. 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.