Fuel Tank Replacement

Fuel Tank:

WARNING: Gasoline or gasoline vapors are highly flammable. If an ignition source is present, a fire can occur. Never drain or store gasoline in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

REMOVE OR DISCONNECT
1. Drain fuel from tank.
2. Raise vehicle.
3. Fuel tank plastic shield.
4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.
5. Support the fuel tank and remove the tank brackets.
6. Lower the fuel tank, disconnect the fuel/vapor hoses, and the electrical connections at the sender.
7. Fuel sender and seal ring, using tool J 36608. Discard the old seal ring. Purge tank, if being repaired.

INSTALL OR CONNECT
1. New seal ring and reinstall sender using tool J 36608.
2. Raise tank slightly and reconnect the fuel/vapor hoses and the electrical connections at the sender. Ensure the ground strap is also reinstalled to the body.
3. Raise the tank fully and reinstall the fuel tank filler neck to the tank. Tighten clamp.
4. Fuel tank brackets with insulator strips in place. Tighten the strap nuts to 45 Nm (33 lb. ft.).



NOTICE: The strap nuts must be tightened by steps, alternating between the four nuts until the specified torque is reached. Otherwise, the bottom of the tank will flex upward and the fuel gage will indicate fuel remaining when the tank "runs dry."


5. Fuel tank plastic shield.
6. Replenish fuel. Reinstall fuel tank filler cap.
7. 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.
8. Check for leaks.

Tighten
1. All bolts.