Fuel Tank Replacement
REMOVAL PROCEDURECAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank).
4. Disconnect the fuel fill pipe from the fuel fill pipe housing.
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Disconnect the fuel fill pipe ground strap.
7. Remove the Evaporative Emission (EVAP) canister.
8. Disconnect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes.
9. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
10. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
11. Remove the fuel tank shield.
12. With the aid of an assistant, support the fuel tank.
NOTE: Refer to Fuel Tank Straps Notice in Cautions and Notices.
13. Remove the fuel tank strap attaching bolts.
14. Remove the fuel tank straps.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Remove the fuel feed pipe (4) and the fuel return pipe (5) from the fuel sender (2) and the retaining clips (6).
18. Remove the EVAP pipe (1) from the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
19. Remove the fuel sender assembly from the fuel tank.
20. Remove the fuel fill and vent hose and pipe assembly from the fuel tank.
INSTALLATION PROCEDURE
1. Install the fuel sender assembly to the fuel tank.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the fuel fill and vent hose and pipe assembly to the fuel tank.
Tighten
Tighten the hose clamp to 2.5 N.m (22 lb in)
3. Connect the EVAP pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
4. Connect the fuel feed pipe (4) and the fuel return pipe (5) to the fuel sender and the retaining clips.
5. With the aid of an assistant, position and support the fuel tank.
6. Install the fuel tank straps.
7. Install the fuel tank strap attaching bolts.
Tighten
Tighten the bolts to 40 N.m (30 lb ft).
8. Install the fuel tank shield to the fuel tank clips.
9. Install the fuel tank shield to frame bolts.
Tighten
Tighten the bolts to 18 N.m (13 lb ft).
10. Connect the fuel sender and the fuel pressure sensor electrical connectors.
11. Remove the caps from the fuel and EVAP pipes.
12. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes.
13. Install the EVAP canister.
14. Connect the fuel fill pipe ground strap.
Tighten
Tighten the fuel fill pipe ground strap bolt to 9 N.m (80 lb in).
15. Lower the vehicle.
16. Connect the fuel fill pipe to the fuel fill pipe housing.
Tighten
Tighten the fuel fill pipe housing screws to 2.3 N.m (20 lb in).
17. Refill the fuel tank.
18. Install the fuel filler cap.
19. Connect the negative battery cable.
20. Inspect for leaks.
20.1. Turn the ignition ON for 2 seconds.
20.2. Turn the ignition OFF for 10 seconds.
20.3. Turn the ignition ON.
20.4. Inspect for fuel leaks.