2DR Utility
REMOVAL PROCEDUREDisconnect the negative battery cable under the following circumstances:
- When installing an electrical unit.
- When a tool or equipment could easily come Into contact with "live" exposed electrical terminals.
WARNING: Failure to disconnect the negative battery terminal may result in personal injury or damage to the vehicle's components. Turn OFF the vehicle ignition, unless instructed otherwise.
1. Remove negative battery cable.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining. Fuel Tank Draining
3. Raise the vehicle.
4. Remove the fuel tank off-road shield, if equipped.
5. Loosen the filler neck hose clamp at the fuel tank.
6. Disconnect the fuel tank filler neck from the fuel tank.
7. Support he fuel tank and remove the tank straps and insulator strips, if equipped.
Fuel Tank:
8. Lower the fuel tank shield.
9. Lower the fuel tank. Disconnect the fuel feed and vapor hoses.
10. Disconnect the electrical connections at the sender.
11. Remove the fuel sender assembly and seal ring, using tool J 39765. Discard the old seal ring. Purge the tank, it the tank is being repaired.
INSTALLATION PROCEDURE
1. Install the new seal ring and reinstall the sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.
3. Raise the tank fully.
4. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.
NOTE: 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 in the tank when the tank runs dry.
5. Install the fuel tank brackets with insulator strips in place.
Tighten
- Tighten the strap nuts to 45 Nm (33 lb. ft.).
6. Install the fuel tank off-road shield, if equipped.
7. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
8. 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.
9. Check for fuel leaks.
9.1. Turn ON the ignition switch for 2 seconds.
9.2. Turn OFF the ignition switch for 10 seconds.
9.3. Again, turn the ignition switch to the ON position.
9.4. Check for fuel leaks.