Fuel Tank Replacement (Cab/Chassis - Front)

Fuel Tank Replacement (Cab/Chassis - Front)

Removal Procedure





1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027)Fuel Pressure Relief (CH-48027) Fuel Pressure Relief (CH-48027).

2. Drain the fuel tank. Refer to Fuel Tank Draining Procedures.

3. Remove the fuel shield fasteners (1) and fuel shield (2).





4. Loosen the filler hose clamp (1) and disconnect the filler hose.

5. Disconnect the quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures





6. Disconnect the quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures

7. Disengage the plastic clips (2) from the frame.

8. Disconnect the fuel pump wiring harness connector.

9. If replacing the fuel tank proceed to the next step, otherwise proceed to step 9 in the installation procedure.





10. Support the tank with a suitable jack.

11. Remove the fuel tank strap fasteners (1).





12. Remove the fuel tank (1).

13. If replacing the tank, remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) Service and RepairFuel Tank Fuel Pump Module Replacement (25/35 Series) Service and RepairFuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) Service and RepairFuel Tank Fuel Pump Module Replacement (15 Reg/Ext/Crew Cab w/34 Gal Tank) Service and Repair.

14. Transfer components as necessary.

Installation Procedure





1. If the tank was replaced, install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) Service and RepairFuel Tank Fuel Pump Module Replacement (25/35 Series) Service and RepairFuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) Service and RepairFuel Tank Fuel Pump Module Replacement (15 Reg/Ext/Crew Cab w/34 Gal Tank) Service and Repair.

2. Using a suitable jack, install the fuel tank (1) into position.





Caution:
Refer to Fastener Caution Fastener Caution.

3. Install the fuel tank shield fasteners (1) and tighten to 40 Nm(30 lb ft).





4. Engage the plastic clips (2) to the frame.

5. Connect the quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures

6. Connect the fuel pump wiring harness connector.





7. Tighten the filler hose clamp (1) to 4 Nm(35 lb in).

8. Connect the quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures

9. Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service Procedures.





10. Install the fuel tank shield (2) and fasteners (1) and tighten to 18Nm(13 lb ft).

11. Refill the fuel tank.

12. 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.