Fuel Tank Replacement

REMOVAL PROCEDURE

TOOLS REQUIRED
J 39765 Fuel Sender Locknut Wrench

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

3. Raise vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Loosen the filler neck hose clamp at the fuel tank.
5. Disconnect the fuel tank filler neck from the fuel tank.




6. Disconnect the fuel tank lines (5) from the fuel feed (6), fuel return (4), and [1][2]EVAP (7) chassis pipes.
7. Support the fuel tank.




8. Remove the tank straps and fuel tank shield.
9. Lower the fuel tank enough to access the top of the fuel tank.
10. Remove the fuel sender shield from the top of the fuel sender.
11. Disconnect the electrical connections at the sender.
12. Lower the fuel tank.




13. Remove the fuel sender lock ring, using the tool J 39765.
14. Remove the fuel sender and seal ring.
15. Discard the old seal ring.

INSTALLATION PROCEDURE




1. Install a new seal ring.

NOTE: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

2. Reinstall the fuel tank sending unit.
3. Reinstall the fuel tank sender lock ring using tool J39765.
4. Install the fuel tank bottom shield with insulator strips in place.
5. Raise the tank under the vehicle to allow reconnection of electrical connections.




6. Install the fuel sender shield on top of the fuel tank.
Ensure the ground strap is reinstalled to the body.
7. Raise the tank fully.
8. Reconnect the fuel tank lines (5) to the fuel feed (6), fuel return (4), and [1][2]EVAP (7) chassis pipes.
9. Reinstall the fuel tank filler neck to the tank.

NOTE: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.

IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.




10. Install the fuel tank brackets with insulator strips in place.
11. Loosely assemble the inboard bolts and spacers through the fuel tank brackets to the frame mounted weld nuts.
12. Loosely assemble the outboard bolts, washers, spacers and jamb nuts through the fuel tank brackets to the frame mounted jamb nuts.

NOTE: Refer to Fastener Notice in Service Precautions.

13. Tighten the inboard strap bolts first.

Tighten
Tighten the inboard strap bolts to 35 N.m (26 lb ft).

14. Tighten the outboard strap bolts next.

Tighten
Tighten the outboard strap bolts to 9 N.m (80 lb in).

15. Tighten the jam nuts against the side rail (outboard) last.

Tighten
Tighten the jam nuts to 35 N.m (26 lb ft).

16. Lower the vehicle.
17. Replenish fuel.
18. Reinstall fuel tank filler cap.
19. Reconnect the negative battery cable.
If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
20. Inspect for leaks.
20.1. Turn ON the ignition switch for 2 seconds.
20.2. Turn OFF the ignition switch for 10 seconds.
20.3. Turn ON the ignition switch.
20.4. Inspect for fuel leaks.