Fuel Tank Replacement
Fuel Tank Replacement
Removal Procedure
J 34730-1A, Fuel Pressure Gauge
Caution: Provide additional support when a vehicle is on a hoist:
^ Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
^ Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
1. Relieve the fuel system pressure.
2. Raise the vehicle and suitably support.
3. Drain the fuel tank.
Important: If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.
4. Disconnect the fuel feed pipe (1) at the in-line fuel filter and return pipe (2) near the in-line fuel filter.
5. Grasp both ends of the fuel feed pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick connect fittings.
Caution: Wear safety glasses when using compressed air in order to prevent eye injury.
6. Blow out dirt from quick connect fittings, using compressed air.
7. Squeeze plastic tabs of male end connector of fuel filter.
8. Pull connection apart.
9. Repeat steps 5 through 8 for the other fitting.
10. Disconnect the clamps (3) at the fuel fill hose (2) and vent hose (1) at the fuel tank (4).
11. Disconnect the fuel sender (1) electrical connector.
12. Remove the exhaust heat shield screws and reposition shield.
Notice: Do not bend the fuel tank straps as this may damage the straps.
13. Support the fuel tank (4) and remove the fuel tank retaining strap bolts (2).
14. Lower the tank and disconnect the EVAP pipe.
15. Inspect the connectors for dirt and damage. Clean or replace as required.
16. Remove the fuel sender assembly.
Installation Procedure
1. Install fuel sender assembly into the fuel tank (1).
Important: Assure proper location of fuel sender pipes.
2. Install fuel tank retaining straps (3) attaching bolts with the aid of an assistant to the fuel tank (4).
3. Raise fuel tank and connect EVAP pipe.
Tighten
Tighten the fuel tank strap bolts to 34 Nm (26 lb ft).
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
4. Install exhaust heat shield screws.
5. Connect fuel sender electrical connector.
6. Connect the clamps (3) at the fuel filler neck (2) and fill pipe vent pipe (1) to the fuel tank.
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.
7. Apply a few drops of clean engine oil to the male connector pipe ends.
8. Push connectors together to cause the retaining tabs/fingers to snap into place.
9. Pull on both ends of each connection to make sure connection is secure, once installed.
10. Lower the vehicle.
11. Install the negative battery cable.
12. Add fuel and install fuel filler cap.
12.1. Turn ignition switch to ON for 2 seconds.
12.2. Turn the ignition switch to OFF for 5 seconds.
12.3. Turn the ignition switch ON.
12.4. Check for fuel leaks.