Fuel tank — removal and installation Ford F150
Warning: Gasoline is extremely flammable, so take extra precautions when you work on any part of the fuel system. See the Warning in Fuel pressure relief procedure.
Note: Don’t begin this procedure until the gauge indicates that the tank is empty or nearly empty. If the tank must be removed when it’s full (for example, if the fuel pump malfunctions), siphon any remaining fuel from the tank prior to removal.
Removal
1. Relieve the fuel system pressure (see Fuel pressure relief procedure).
2. Remove the fuel filler cap to relieve fuel tank pressure.
3. Disconnect the cable from the negative terminal of the battery (see Battery – disconnection and reconnection).
4. If the tank is full or nearly full, siphon the fuel into an approved container using a siphoning kit available at most auto parts stores.
Warning: DO NOT start the siphoning action by mouth! Use a siphoning kit (available at most auto parts stores).
5. Raise the vehicle and support it securely on jackstands.
Fuel tank shield
6. if equipped, remove the fuel tank shield
Disconnect the lines at the front of the tank
7. Disconnect the fuel line and EVAP vapor line quick-connect fittings at the front of the tank
Disconnect the fuel tank filler hose vent tube from the fuel pump module
8. Disconnect the fuel tank filler hose vent tube quick-connect fitting from the top of the fuel pump module
9. Disconnect the electrical connectors from the fuel pump module and EVAP sensors.
Loosening the fuel filler hose clamp
10. Loosen the clamp and disconnect the the fuel tank filler hose from the filler pipe
11. Place a jack under the tank, then raise the jack until it’s supporting the tank.
Remove the fuel tank strap bolts…
… then swing the straps down (the straps can be turned 90 degrees and detached from the frame)
12. Remove the bolts that retain the fuel tank straps, then swing the straps down
13. Lower the tank far enough to unplug any vapor lines or wire harness brackets that may be difficult to reach when the fuel tank is in the vehicle.
14. Slowly lower the jack while steadying the tank. Remove the tank from the vehicle.
15. If you’re replacing the tank, or having it cleaned or repaired, refer to Fuel tank – cleaning and repair.
16. Refer to Fuel pump/fuel pump module – removal and installation to remove and install the fuel pump (gasoline) or sending unit (diesel).
Installation
17. Installation is the reverse of removal. Clean engine oil can be used as an assembly aid when pushing the fuel filler neck back into the tank.
18. Carefully angle the fuel tank filler neck into the filler pipe assembly and lift the tank into place. Tight the fuel tank strap bolts to the torque listed in this Chapter’s Specifications.
19. Install the shield to the tank.
20. Turn the ignition on and check for leaks.