Fuel Tank Replacement (Extended Cab - Side Tank)

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J34730-1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.
5. Disconnect the fuel tank filler neck hose (2) from the fuel tank.
6. Disconnect the fuel tank vent hose (3) from the fuel tank.




7. Support the fuel tank.
8. Remove the rear fuel tank strap.




9. Remove the frame mounted bracket and front fuel tank strap.




10. With the aid of an assistant, lower and support the fuel tank and shield. Lower the fuel tank shield and the fuel tank to access the top to the fuel tank.




11. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
12. Disconnect the fuel pipes (1) and the vapor pipe (2).
13. Disconnect the electrical connections at the sender.
14. Remove the fuel tank and shield.
15. Remove the fuel sender.

INSTALLATION PROCEDURE




1. Install the fuel tank insulators.




2. Install the fuel sender.
3. Raise the fuel tank.
4. Connect the fuel pipes (1) and the vapor pipe (2) at the sender.
5. Connect the electrical connections at the sender.

IMPORTANT: When removing or replacing the fuel tank the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.




6. Raise the fuel tank and shield fully.

NOTE: Refer to Fastener Notice in Service Precautions.

7. Install the front fuel tank strap and the frame mounted bracket.

Tighten
^ Tighten the front strap nut to 13 N.m (115 lb in.).
^ Tighten the frame mounted bracket nuts to 33 N.m (24 lb if).




8. Install the rear fuel tank strap.

Tighten
Tighten the rear strap bolt to 13 N.m (115 lb in.).




9. Connect the fuel tank filler neck hose (2) to the fuel tank.
10. Connect the fuel tank vent hose (3) to the fuel tank.

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

11. Lower the vehicle.
12. Refill the fuel system.
13. Install the fuel filler cap.
14. Connect the negative battery cable.
15. Inspect for fuel leaks.
15.1. Turn ON the ignition for 2 seconds.
15.2. Turn OFF the ignition for 10 seconds.
15.3. Turn ON the ignition.
15.4. Inspect for fuel leaks.