Fuel Tank Replacement (4-Door)

REMOVAL PROCEDURE

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




1. Disconnect the negative battery cable.
2. Drain the fuel from the fuel tank.
3. Raise the vehicle. (This must be done with a frame hoist to allow the rear suspension to hang.)
4. Remove the filler hose and vent hose from the fuel tank.




5. Support the fuel tank and remove the fuel tank straps.




6. Lower the fuel tank shield and the fuel tank.




7. Disconnect the fuel feed and vapor hoses.
8. Disconnect the electrical connector at the sender.




9. Remove the fuel tank.




10. Remove the fuel sender and the seal ring. 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.
2. Raise the tank and reconnect the electrical connector at the sender.




3. Reconnect the fuel feed and vapor hoses.




4. Raise the fuel tank fully and reinstall the tank shield.

NOTE: Refer to Fastener Notice in Cautions and Notices.




5. Reinstall the tank straps.

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.

Tighten
Tighten the bolts to 35 N.m (47 lb ft).




6. Reinstall the filler 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.