Rear - Cab/Chassis

TOOLS REQUIRED
J 44581 Fuel Line Disconnect Tool

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Loosen the fuel fill vent hose clamps at the tank.
3. Remove the fuel fill pipe and vent hose from the tank.
4. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.




5. Disconnect the fuel tank pressure sensor electrical connector (2).




6. Disconnect the fuel feed pipe from the sending unit.
7. Using J 44581, disconnect the fuel return pipe from the sending unit.
8. Raise and suitably support the vehicle. Refer to Vehicle Lifting.




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




12. Remove the fuel tank strap bolts.

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions.

13. Remove the fuel tank straps.
14. Lower the fuel tank.
15. With the aid of an assistant, place the fuel tank in a suitable work area.
16. If replacing the fuel tank, remove the sending unit.
17. Cap the fuel and EVAP pipes in order to prevent possible fuel/EVAP system contamination.

INSTALLATION PROCEDURE




1. Remove the caps from the fuel and EVAP pipes.
2. If the fuel tank was replaced, install the sending unit.
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.

NOTE: Refer to Fastener Notice in Service Precautions.

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.




12. Connect the fuel tank pressure sensor electrical connector (2).




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

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

15. Fill the fuel tank.
16. Install the fuel fill cap.
17. Connect the negative battery cable.
18. Use the following procedure in order to inspect for leaks:
18.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
18.2. Turn the ignition OFF for 10 seconds.
18.3. Turn the ignition ON, with the engine OFF.
18.4. Inspect for fuel leaks.