Fuel Tank Replacement (Side Tank)

REMOVAL PROCEDURE

TOOLS REQUIRED
J 39765 Fuel Sender Locknut Wrench.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Drain the fuel from the tank.
3. Raise the vehicle.
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 straps and insulator strips, if equipped.




6. Remove the frame mounted bracket.




7. Lower the fuel tank shield.




8. Lower the fuel tank.




9. Disconnect the fuel feed (1) and vapor (2) hoses. Disconnect the electrical connector at the sender.




10. Remove the fuel sender assembly and seal ring, using tool J 39765. Discard the old seal ring.

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 (1), vapor (2) hoses and the electrical connector at the sender.




3. Raise the fuel tank fully.




4. Install the fuel tank shield.
5. Install the fuel tank straps and fastening hardware.

IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.




6. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.




7. Install the frame mounted bracket.

Tighten
Tighten the fasteners to 33 N.m (45 lb ft).

NOTE:
^ Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank runs dry.
^ Refer to Fastener Notice in Cautions and Notices.




8. Install the fuel tank brackets with insulator strips in place.

Tighten
Tighten the strap nuts to 13 N.m (115 lb in).

9. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
10. 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.
11. Check for fuel leaks.
11.1. Turn ON the ignition switch for 2 seconds.
11.2. Turn OFF the ignition switch for 10 seconds.
11.3. Again, turn the ignition switch to the ON position.
11.4. Check for fuel leaks.