Fuel Tank Removal and Installation

FUEL TANK

REMOVAL

WARNING:
- Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

CAUTION: The fuel filter is located near the left side frame rail on the fuel tank. Correct placement of the vehicle hoisting equipment is necessary to prevent damaging any fuel system components.

1. Release the fuel system pressure.
2. Drain the fuel tank.







3. Disconnect the vapor hoses at the rear of the fuel tank.







4. If equipped, remove the fuel tank skid plate.







5. NOTE: The 4.6L and 5.4L (2V) engines are equipped with returnless fuel systems. The 5.4L (4V) engine is equipped with a return-type fuel system.

Disconnect the vapor hose and the fuel hose(s) forward of the fuel tank.







6. CAUTION: Do not support the fuel tank directly beneath the fuel pump mounting area. Damage to the fuel pump assembly can occur.

Position a suitable jack under the fuel tank.







7. NOTE: The location of the fuel vent hose is critical to fuel system operation. Note the routing of the fuel vent hose at this time.

Remove the fuel tank front and rear support straps and lower the front of the fuel tank approximately 25 mm (1 in).







8. Loosen the clamp and disconnect the vent hose from the fuel tank vent spout.







9. Disconnect the fuel pump electrical connector.
10. Remove the fuel tank from the vehicle.







11. NOTE: The clamp is located on the top of the left side frame rail.

Loosen the clamp and disconnect the hose from the fuel fill pipe vent tube.







12. NOTE: The fuel tank pressure sensor is located forward of the left rear wheel well above the frame rail.

Disconnect the fuel tank pressure sensor electrical connector.







13. Remove the vent hose assembly.

INSTALLATION







1. Install the vent hose to the fuel tank vent spout.







2. CAUTION:
- Do not support the fuel tank directly beneath the fuel pump mounting area. Damage to the fuel pump assembly can occur.
- Correct routing of the fuel vent hose and fuel tank pressure sensor is critical to fuel system operation. Make sure that the fuel vent hose and fuel tank pressure sensor are routed above the crossmember and brake cables.

NOTE: If a new fuel tank is being installed, transfer the fuel vent hose and fuel tank pressure sensor to the new tank.

Position the fuel tank in the vehicle.







3. Connect the fuel tank pressure sensor electrical connector.







4. Connect the fuel pump electrical connector.







5. Install the front and rear support straps.







6. If equipped, install the fuel tank skid plate.







7. NOTE: The 4.6L and 5.4L (2V) engines are equipped with returnless fuel Systems. The 5.4L (4V) engine is equipped with a return-type fuel system.

Connect the vapor hose and the fuel hose(s) forward of the fuel tank.







8. Connect the vapor hoses at the rear of the fuel tank.







9. Connect the vent hose to the filler pipe.







10. Connect the fuel filler hose.
11. Fill the fuel tank.