Fuel Tank Replacement (15 Ext/Crew Cab w/26 gal Tank)

Fuel Tank Replacement (15 Ext/Crew Cab w/26 gal Tank)

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.
3. Remove the fuel tank shield bolts, if equipped.




4. Remove the fuel tank shield from the fuel tank shield tabs (1), if equipped.




5. Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis line.
6. Disconnect the fuel tank EVAP line quick connect fitting (3) from the EVAP canister.
7. Cap the fuel and EVAP lines in order to prevent possible system contamination.




8. Place a suitable adjustable jack under the fuel tank.
9. Remove the fuel tank strap bolts.
10. Remove the fuel tank straps.

Important: When lowering the tank, ensure that the fill neck on the tank does not get hung up on the chassis wiring harness.

11. Lower the fuel tank half way.

1. Loosen the fuel fill pipe clamp at the fuel tank.
2. Separate the fuel fill pipe from the fuel tank.

12. Disconnect the chassis wiring harness clip at the frame crossmember.
13. Lower the fuel tank until the electrical connections are accessible.




14. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor.
15. Disconnect the chassis wiring harness electrical connector from the fuel tank module.
16. Completely lower the fuel tank.
17. With the aid of an assistant, place the fuel tank in a suitable work area.
18. If replacing the fuel tank proceed to the next step, otherwise proceed to step 10 in the installation procedure.




19. Remove the fuel tank shield push on retainers.
20. Remove the fuel tank shield.




21. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module.
22. Remove the fuel feed pipe from the fuel tank clips (1).




23. Disconnect the EVAP pipe quick connect fitting from the fuel tank module.
24. Remove the EVAP pipe from the fuel tank clips (1).




25. Disconnect the EVAP pipe quick connect fittings from the rollover valve and the fuel tank module.
26. Remove the EVAP pipe from the fuel tank clips (1 and 2).
27. Remove the fuel tank module.

Installation Procedure




1. Install the fuel tank module.
2. Position and connect the EVAP pipe quick connect fittings to the rollover valve and the fuel tank module.
3. Install the EVAP pipe to the fuel tank clips (1 and 2).




4. Position and connect the EVAP pipe quick connect fitting to the fuel tank module.
5. Install the EVAP pipe to the fuel tank clips (1).




6. Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
7. Install the fuel feed pipe to the fuel tank clips (1).




8. Position and install the fuel tank shield.
9. Install the fuel tank shield push on retainers.




10. With the aid of an assistant, place the fuel tank in a the adjustable jack.
11. Raise the fuel tank until the electrical connections can be made.
12. Connect the chassis wiring harness electrical connector to the fuel tank module.
13. Connect the chassis wiring harness electrical connector from the fuel pressure sensor.
14. Completely raise the fuel tank into position.




15. Install the fuel tank straps.

Notice: Refer to Fastener Notice.

16. Install the fuel tank strap bolts.

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

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




18. Remove the caps from the fuel and EVAP lines.
19. Connect the fuel tank EVAP line quick connect fitting (3) to the EVAP canister.
20. Connect the fuel tank fuel feed line quick connect fitting (1) to the chassis line.




21. Position and install the fuel tank shield onto the fuel tank shield tabs (1), if equipped.




22. Install the fuel tank shield bolts, if equipped.

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

23. Refill the fuel tank.
24. Install the fuel cap.
25. Connect the negative battery cable.
26. 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.