Removal and Replacement

Fuel Tank Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH 48027) (Fuel Pressure Relief (CH-48027))Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027)).
2. Drain the fuel tank. Refer to Fuel Tank Draining (Non E-85) (Procedures).
3. Raise and support the vehicle, high enough to access the top of the fuel tank through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle (Service and Repair).
4. Remove the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Panel Liner Replacement (Service and Repair).
5. Loosen the fuel fill hose clamp (2) at the fuel tank.
6. Disconnect the evaporative emission (EVAP) line (1) quick connect fitting from the fill tube vent tube. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
7. Separate the fuel fill hose from the fuel tank.
8. Disconnect the chassis wiring harness electrical connectors from the pressure sensor and the module.
9. Disengage the harness from the retainer on the fuel tank.
10. Raise the vehicle completely.




11. Disconnect and remove the middle EVAP vapor line (1) from the fuel tank (3) and the EVAP canister (5). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




12. Disconnect the fuel feed line quick connect fitting from the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).

Caution: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.




13. Remove the upper fuel tank strap bolt.
14. Remove the upper fuel tank strap.
15. Support the fuel tank with an adjustable jack.




16. Remove the lower fuel tank strap bolt.
17. Remove the lower fuel tank strap.
18. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
19. Place the fuel tank in a suitable work area.
20. If the fuel tank is not being replaced, proceed to the Installation Procedure.

Disassembly Procedure




1. Disconnect the EVAP line (1) quick connect fittings from the module and the vent valve. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
2. Remove the EVAP line from the clip on the side of the fuel tank.
3. Disengage the EVAP line from the retaining features molded into the fuel tank and remove the EVAP line.
4. Disconnect the fuel feed line (2) quick connect fitting from the module. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Disengage the fuel feed line from the retaining feature molded into the fuel tank and remove the fuel line.
6. Remove the fuel tank module from the fuel tank. Refer to Fuel Tank Module Replacement (Service and Repair).

Assembly Procedure




1. Install the fuel tank module to the fuel tank. Refer to Fuel Tank Module Replacement (Service and Repair).
2. Connect the fuel feed line (2) quick connect fitting to the module. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
3. Engage the fuel feed line to the retaining feature molded into the fuel tank.
4. Connect the EVAP line (1) quick connect fittings to the module and the vent valve. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Engage the EVAP line to the retaining features molded into the fuel tank.
6. Install the EVAP line to the clip on the side of the fuel tank.

Installation Procedure




1. With the aid of an assistant, carefully position and support the fuel tank to the vehicle.
2. Install the lower fuel tank strap.
3. Install the lower fuel tank strap bolt.
Do not tighten at this time.




4. Install the upper fuel tank strap.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the upper fuel tank strap bolt.

Tighten the bolts to 32 Nm (24 lb ft).




6. Connect the fuel feed line quick connect fitting to the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




7. Install and connect the middle EVAP vapor line (1) to the fuel tank (3) and the EVAP canister (5). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




8. Lower the vehicle only enough to gain access to the fuel tank through the wheelhouse.
9. Connect the chassis wiring harness electrical connectors to the pressure sensor and the module.
10. Secure the harness to the retainer on the fuel tank.
11. Install the fuel fill hose to the fuel tank.
12. Connect the fuel tank EVAP line (1) quick connect fitting to the fill tube vent tube. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
13. Tighten the fuel fill hose (2) at the fuel tank.

Tighten clamp to 2.5 Nm (22 lb in).

14. Install the left rear pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Panel Liner Replacement (Service and Repair).
15. Lower the vehicle.
16. Refill the fuel tank.
17. Install the fuel fill cap.
18. Inspect for leaks.

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