Auxiliary Fuel Tank Replacement

Auxiliary Fuel Tank Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (CH-48027).
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
3. Drain the fuel tank. Refer to Fuel Tank Draining (Procedures).
4. Remove the fuel tank shield bolts (1) and the fuel tank shield (2).




5. Loosen the fuel fill (1) and vent pipe (2) hose clamps.
6. Disconnect the hoses.




7. With the aid of an assistant, support the fuel tank.
8. Disconnect the evaporative emissions lines and the fuel lines. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) and Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service)
9. Disconnect the electrical connectors.
10. Remove the fuel tank strap bolts (1) and the auxiliary fuel tank (2).
11. Remove the fuel pump module from the fuel tank. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (Service and Repair).
12. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

Installation Procedure




1. Install the fuel pump module to the fuel tank. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (Service and Repair).
2. Remove the caps from the fuel and EVAP pipes.
3. With the aid of an assistant, support and partially raise the fuel tank.
4. Connect the electrical connectors.
5. Connect the evaporative emissions lines and the fuel lines. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) and Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service)
6. With the aid of an assistant, support the auxiliary fuel tank.
7. Install the auxiliary fuel tank (1).

Caution: Refer to Fastener Caution (Fastener Caution).

8. Install the fuel tank strap attaching bolts (2) and tighten to 40 Nm (30 lb ft).




9. Connect and tighten the fuel fill (1) and vent pipe (2) hose clamps to 4 Nm (35 lb in).




10. Install the fuel tank shield (2) and the fuel tank shield bolts (1) and tighten to 18 Nm (13 lb ft).
11. Refill the fuel tank.
12. Install the fuel filler cap.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (Service and Repair) in Engine Electrical.
14. Use the following procedure in order to inspect for leaks:

1. Turn ON the ignition, with the engine OFF, for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.