4DR Utility
REMOVAL PROCEDURE1. Drain the fuel from the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Raise the vehicle. (This must be done with a frame hoist to allow the rear suspension to hang.)
Diagram:
3. Remove the filler hose and vent hose from the fuel tank.
Diagram:
4. Support the fuel tank and remove the fuel tank straps.
Diagram:
5. Lower the fuel tank shield and the fuel tank.
Diagram:
6. Disconnect the fuel feed and vapor hoses. Refer to Quick Connect Fitting(s) Service (Metal Collar).
7. Disconnect the electrical connector at the sender.
Diagram:
8. Remove the fuel tank.
Fuel Sender Assembly:
9. Remove the fuel sender and the seal ring, using tool J 39785. Discard the old seal ring. Purge the tank, if 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 and reconnect the electrical connector at the sender.
3. Reconnect the fuel teed and vapor hoses. Refer to Quick Connect Fitting(s) Service (Metal Collar).
4. Raise the tank fully and reinstall the tank shield.
5. Reinstall the tank straps. Tighten the bolts to 12 Nm (10 lb. ft.).
6. Reinstall the tiller hose and the vent hose to the tank.
7. Replenish the fuel. Reinstall the fuel tank filler cap.
8. Reconnect the negative battery cable.
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.