Fuel Tank Replacement Pickup

1. Drain the fuel tank. Refer to Fuel Tank Draining .
2. Remove the fuel tank filler housing to body screws (1), and retainer (2).



3. Remove the fuel tank filler housing to fuel tank fill pipe screws.
4. Remove the fuel tank filler housing.



5. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Remove the fuel tank ground strap bolt.
8. Remove the fuel tank ground strap



9. Loosen the fuel tank fill pipe clamp at the fuel tank.
10. Remove the fuel tank fill pipe from the fuel tank and vehicle.
11. Remove the fuel system cooler. Refer to Fuel Cooler Replacement .



12. Remove the fuel tank shield bolts.
13. Remove the fuel tank shield.



14. Disconnect the fuel feed and return pipes from the fuel tank pipes. Refer to Metal Collar Quick Connect Fitting Service .
15. Cap the fuel pipes in order to prevent possible fuel system contamination.
16. Place a suitable adjustable jack under the fuel tank.

Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.




17. Remove the fuel tank strap bolts.
18. Remove the fuel tank straps.
19. Remove the fuel tank.
20. Lower the fuel tank until the electrical connector is accessible.
21. Disconnect the sending unit electrical connector.
22. With the aid of an assistant, place the fuel tank in a suitable work area.



23. Disconnect and remove the fuel feed and return pipes from the sending unit (1) and retaining clips (3). Refer to Plastic Collar Quick Connect Fitting Service .
24. If replacing the fuel tank, remove the sending unit. Refer to Fuel Sender Assembly Replacement .

1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
2. Install and connect the fuel feed and return pipes to the sending unit (1) and retaining clips (3). Refer to Plastic Collar Quick Connect Fitting Service .



3. With the aid of an assistant, place the fuel tank on the jack.
4. Raise the fuel tank until the electrical connector is accessible.
5. Connect the sending unit electrical connector.
6. Install the fuel tank.
7. Install the fuel tank straps.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

9. Remove the jack from under the fuel tank.



10. Remove the caps from the fuel pipes.
11. Connect the fuel feed and return pipes from the fuel tank pipes. Refer to Metal Collar Quick Connect Fitting Service .



12. Install the fuel tank shield.
13. Install the fuel tank shield bolts.

Tighten
Tighten the bolts to 18 N·m (13 lb ft).

14. Install the fuel system cooler. Refer to Fuel Cooler Replacement .



15. Install the fuel tank fill pipe to the fuel tank and vehicle.
16. Tighten the fuel tank fill pipe clamp at the fuel tank.
17. Install the fuel tank ground strap
18. Install the fuel tank ground strap bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in)

19. Lower the vehicle.



20. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.



21. Install the fuel tank filler housing.
22. Install the fuel tank filler housing to fuel tank fill pipe screws.

Tighten
Tighten the screws to 2.3 N·m (20 lb in)




23. Install the fuel tank filler housing to body screws (1), and retainer (2).

Tighten
Tighten the screws to 2.3 N·m (20 lb in)

24. Fill the fuel tank.
25. Install the fuel fill cap.
26. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
27. Prime the fuel system.
28. Start the engine and test for fuel leaks.

Fuel Tank Replacement Cab/Chassis - Front

1. Disconnect the fuel feed and pressure balance rear pipes. Refer to Metal Collar Quick Connect Fitting Service .



2. Loosen the fuel fill and vent hose clamps at the fuel tank.
3. Remove the fuel fill pipe and vent hose from the tank.
4. Drain the fuel tank. Refer to Fuel Tank Draining .
5. Disconnect the sending unit electrical connector.



6. Disconnect the fuel feed/return pipes from the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



8. Remove the fuel tank shield bolts.
9. Remove the fuel tank shield.
10. Place a suitable adjustable jack under the fuel tank.

Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.




11. Remove the fuel tank strap bolts.
12. Remove the fuel tank straps (1).
13. Lower the fuel tank.
14. With the aid of an assistant, place the fuel tank in a suitable work area.
15. Cap the fuel pipes on the vehicle in order to prevent possible fuel system contamination.
16. If replacing the fuel tank, remove the sending unit. Refer to Fuel Sender Assembly Replacement .

1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
2. Remove the caps from the fuel pipes.
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 (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

7. Remove the jack from under the fuel tank.



8. Install the fuel tank shield.
9. Install the fuel tank shield bolts.

Tighten
Tighten the bolts to 18 N·m (13 lb ft).

10. Lower the vehicle.



11. Connect the fuel feed/return pipes at the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
12. Connect the sending unit electrical connector.



13. Install the fuel fill pipe and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps at the fuel tank.

Tighten
Tighten the clamps to 2.5 N·m (22 lb in).




15. Connect the fuel feed and pressure balance rear pipes. Refer to Metal Collar Quick Connect Fitting Service .
16. Fill the fuel tank.
17. Install the fuel fill cap.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
19. Prime the fuel system.
20. Start the engine and test for fuel leaks.

Fuel Tank Replacement Cab/Chassis - Rear

1. Loosen the fuel fill and vent hose clamps at the tank.
2. Remove the fuel fill and vent hose from the tank.
3. Drain the fuel tank. Refer to Fuel Tank Draining .



4. Disconnect the sending unit electrical connector (2).



5. Disconnect the fuel feed/return pipes from the sending unit. Refer to Metal Collar Quick Connect Fitting Service .
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



7. Remove the fuel tank shield bolts.
8. Remove the fuel tank shield.
9. Place a suitable adjustable jack under the fuel tank.

Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.




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

1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
2. Remove the caps from the fuel pipes.
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.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the fuel tank strap bolts.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

7. Remove the jack from under the fuel tank.



8. Install the fuel tank shield.
9. Install the fuel tank shield bolts.

Tighten
Tighten the bolts to 18 N·m (13 lb ft).

10. Lower the vehicle.



11. Connect the fuel feed/return pipes to the sending unit. Refer to Metal Collar Quick Connect Fitting Service .



12. Connect the sending unit electrical connector (2).



13. Install the fuel fill and vent hose to the tank.
14. Tighten the fuel fill and vent hose clamps at the tank.

Tighten
Tighten the hose clamps to 2.5 N·m (22 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 in Engine Electrical.
18. Command the fuel transfer pump on with a scan tool .
19. Test for fuel leaks.