How to Install a 1997 Ford F-150 Fuel Tank

The 1997 Ford F-150 base model is powered by a 4.2-liter six-cylinder engine with a five-speed manual transmission and two-wheel-drive configuration. With a third hinged door and an added rear seat, the F-150 was designed to accommodate more than just three people. At just 15 mpg average for city driving, the F-150 had to be equipped with a 25-gallon tank so the driver didnt have to stop at every gas station. The fuel tank is located on the driver side and is secured to the truck with a strap at each end of the tank.

Instructions

Removal

1

Lift the vehicle hood and support it with the hood prop rod. Locate the Schrader valve on the fuel rail and remove the plastic protective cap. Attach the fuel pressure gauge to the Schrader valve and direct the pressure gauge outlet tube into the large gas can. Slowly open the manual valve on the fuel pressure gauge. When the fuel has finished flowing into the gas can, the fuel pressure has been relieved.

2

Lie under the vehicle on the driver side and remove the rear evaporative emissions valve by turning it counterclockwise by hand and lifting it off of the tank. Place the siphon pump into the valve opening. Place the large gas can somewhere near the gas tank and siphon as much fuel out of the tank as possible. Cap off the gas can and store it in a safe place until needed.

3

Remove the six bolts securing the fuel tank skid plate to the under carriage of the truck with the socket, ratchet extension and ratchet. Remove the skid plate.

4

Remove both clamps for the fuel filler neck and the fuel filler vent tube and remove both hoses from the fuel tank.

5

Disconnect the fuel lines by sliding the fuel line disconnect tool into the fuel line quick disconnect fittings at the fuel pump. There may be plastic clips installed from the factory that need to be removed with a pair of pliers

6

Disconnect the remaining evap hose on the front of the tank and unplug the fuel transducer connector. Disconnect the electrical pigtail for the fuel pump and set the wiring harness aside.

7

Place the floor jack under the middle of the fuel tank and raise the jack arm until there is just enough room to slide the wood block between the fuel tank and the jack arm. Center the wood on the jack arm and lift the jack enough for the wood to contact the fuel tank.

8

Remove the fuel tank strap bolts at each end of the gas tank and remove the fuel tank straps. Support the gas tank with one hand and slowly lower the jack arm, using one hand to help balance the gas tank. Slide the gas tank off of the jack and onto the cardboard. Slide the gas tank out from under the truck.

9

If transferring the fuel pump module to a new tank, remove the fuel pump retainer ring and fuel pump module from the fuel tank

Installation

10

If installing a new tank, ensure the fuel pump, fuel transducer and evap valve are installed correctly.

11

Slide the tank under the truck. Bring the floor jack into position. Set the wood block onto the floor jack arm and have a helper assist you in lifting the fuel tank onto the wood block and jack arm. Support the tank with one arm while lifting to help balance. Position the tank in its proper location and lift the jack arm until the fuel pump makes a connection with the undercarriage.

12

Install the fuel tank straps and tighten the mounting bolts to 30 foot-pounds of torque. Lower the floor jack and wood and remove the floor jack from under the truck.

13

Connect the fuel pump pigtail to the vehicle wiring harness. Connect the evap hose to the evap valve and tighten the clamp to secure it. Plug in the fuel tank transducer electrical connector. Connect the fuel lines to the fuel pump; they should click when properly seated.

14

Install the fuel tank filler neck and the fuel tank filler vent hose. Tighten the clamps to secure them to the fuel tank.

15

Set the fuel tank skid plate into place and install all six mounting bolts. Tighten the skid plate mounting bolts to 13 foot-pounds of torque. Fill the fuel tank with the fuel from the large gas can.

16

Get into the vehicle and turn the ignition key to the "On" position for 10 seconds and then turn it back off. Repeat the on and off process three times and then start the vehicle. Inspect under the vehicle for any leaks.