Rear - Cab/Chassis

FUEL TANK REPLACEMENT (CAB/CHASSIS - REAR)

REMOVAL PROCEDURE




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 Procedure.




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




5. Disconnect the fuel feed/return pipes from the sending unit.
6. Raise and suitably support the vehicle. Refer to Vehicle Lifting.




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




10. Remove the fuel tank strap bolts.

NOTE: Refer to Fuel Tank Strap Fastener Notice in Service Precautions.

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.

INSTALLATION PROCEDURE




1. If the fuel tank was replaced, install the sending unit.
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.

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 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.
18. Command the fuel transfer pump on with a scan tool.
19. Test for fuel leaks.