Removal and Replacement

REMOVAL PROCEDURE
1. Disconnect the negative battery cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

NOTE: The pickup truck fuel filler pipe contains screens. In order to prevent damage to the screens, do not drain the fuel through the fuel tank filler pipe.

3. Raise the vehicle and suitably support.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.




4. Remove the fuel tank shield (1).
5. With aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps (2).
6. Disconnect the fuel sender electrical connector.




7. Disconnect the fuel tank pressure (FTP) sensor electrical connector.
8. Remove the hoses from the fuel sender.
9. Remove the filler, vent and vapor pipes.




10. Remove the fuel tank (2) from vehicle.
11. Remove the sound insulators (1).

INSTALLATION PROCEDURE

IMPORTANT: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.




1. Install the sound insulators (1).
2. With the aid of an assistant, install the fuel tank (2) to the body.
3. Install the hoses to filler, vent and vapor pipes.

CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.




4. Connect the FTP sensor electrical connector.
5. Connect the fuel tank sender electrical connector.





6. Install the fuel tank retaining straps (2).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the bolts to 45 N.m (33 lb ft).

7. Install the fuel tank shield (1).
8. Lower the vehicle.
9. Refill the fuel tank.
10. Reconnect the negative battery cable.
11. Inspect for fuel leaks through the following steps:
11.1. Turn ON the ignition for 2 seconds.
11.2. Turn OFF the ignition for 10 seconds.
11.3. Turn ON the ignition.
11.4. Inspect for fuel leaks.