Fuel Tank Replacement (25 Ext/Crew Cab w/26 gal Tank)

Fuel Tank Replacement (25 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 fill pipe.
4. Disconnect the fuel tank fuel feed (1) and EVAP (2) line quick connect fittings from the chassis lines.
5. Cap the fuel and EVAP lines in order to prevent possible system contamination.




6. Remove the EVAP canister vent solenoid pipe clip (1) from the frame crossmember.
7. Disconnect the EVAP canister pipe quick connect fitting (2) from the fuel tank EVAP pipe.
8. Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister.
9. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid.
10. Remove the chassis wiring harness clip from the fuel tank shield.




11. Insert a small flat bladed tool between the EVAP canister vent solenoid and the fuel tank bracket, disengaging the retainer (1).
12. Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle.
13. Position and secure the EVAP canister vent solenoid out of the way.




14. Place a suitable adjustable jack under the fuel tank.
15. Remove the fuel tank strap bolts.
16. 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.

17. Lower the fuel tank half way.
18. Disconnect the chassis wiring harness clip at the frame crossmember.
19. Lower the fuel tank until the electrical connections are accessible.




20. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor.
21. Disconnect the chassis wiring harness electrical connector from the fuel tank module.
22. Completely lower the fuel tank.
23. With the aid of an assistant, place the fuel tank in a suitable work area.
24. If replacing the fuel tank proceed to the next step, otherwise proceed to step 10 in the installation procedure.




25. Remove the fuel tank shield push on retainers.
26. Remove the fuel tank shield.




27. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module.
28. Remove the fuel feed pipe from the fuel tank clip (1).




29. Remove the EVAP canister purge pipe from the fuel tank clip (1).




30. Disconnect the EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module.
31. Remove the EVAP rear pipe from the fuel tank clips (1 and 2).




32. Disconnect the small EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module.
33. Remove the fuel tank module.

Installation Procedure




1. Install the fuel tank module.
2. Position and connect the small EVAP rear pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.




3. Position and connect the EVAP rear pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
4. Install the EVAP rear pipe to the fuel tank clips (1 and 2).




5. Install the EVAP canister purge pipe to the fuel tank clip (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 clip (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. Unsecure and position the EVAP canister vent solenoid to the fuel tank.
19. Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle.
20. Ensure that the EVAP canister vent solenoid engages the fuel tank bracket retainer (1).




21. Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister.
22. Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe.
23. Install the EVAP canister vent solenoid pipe clip (1) to the frame crossmember.
24. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid.
25. Install the chassis wiring harness clip to the fuel tank shield.




26. Remove the caps from the fuel and EVAP lines.
27. Connect the fuel tank fuel feed (1) and EVAP (2) line quick connect fittings to the chassis lines.
28. Install the fuel tank fill pipe.
29. Refill the fuel tank.
30. Install the fuel cap.
31. Connect the negative battery cable.
32. 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.