Fuel Tank Replacement (Cab/Chassis - Rear)

Fuel Tank Replacement (Cab/Chassis - Rear)

Removal Procedure




1. Loosen the fuel fill and vent hose clamps (1, 2) at the tank.
2. Remove the fuel fill and vent hose from the tank.
3. Drain the fuel tank. Refer to Fuel Tank Draining (Gasoline) (Procedures)Fuel Tank Draining (Emission Reduction Fluid) (Service and Repair).




4. Disconnect the sending unit electrical connector.




5. Disconnect the fuel feed and return lines (1) from the sending unit. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




7. Remove the fuel tank shield bolts.
8. Remove the fuel tank shield.




9. Remove the fuel tank strap bolts.
Caution: Refer to Fuel Tank Strap Fastener Caution (Fuel Tank Strap Fastener Caution).

10. Remove the fuel tank straps.
11. Lower the fuel tank.
12. With the aid of an assistant, place the fuel tank in a suitable work area.
13. Cap the fuel lines in order to prevent possible fuel system contamination.
14. If replacing the fuel tank, remove the sending unit. Refer to Fuel Sender Assembly Replacement (Service and Repair).

Installation Procedure




1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement (Service and Repair).
2. Remove the caps from the fuel lines.
3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank.
5. Install the fuel tank straps.
Caution: Refer to Fastener Caution (Fastener Caution).

6. Install the fuel tank strap bolts and tighten to 40 Nm (30 lb ft).
7. Remove the jack from under the fuel tank.




8. If equipped, install the fuel tank cover.
9. If equipped, install the fuel tank cover bolts and tighten to 18 Nm (13 lb ft).
10. Lower the vehicle.




11. Connect the fuel feed and return lines (1) to the sending unit. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




12. Connect the sending unit electrical connector.




13. Install the fuel fill and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps (1, 2) at the tank to 4 Nm (35 lb in).
15. Fill the fuel tank.
16. Install the fuel fill cap.
17. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (TP2) (Service and Repair).
18. Using a scan tool, command the fuel transfer pump on.
19. Prime the fuel system. Refer to Fuel System Priming (Fuel System Priming).
20. Start the engine. If the engine stalls, repeat the above step.
21. Once the engine starts, inspect for fuel leaks.