Fuel Tank Replacement (4-Door)

REMOVAL PROCEDURE

TOOLS REQUIRED
J 39765 Fuel Sender Locknut Wrench

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Drain the fuel from the tank.

CAUTION: Refer to Lifting and Jacking Notice in Service Precautions.

3. Raise the vehicle.
4. Loosen the filler neck hose clamp at the fuel tank (2).
5. Disconnect the fuel tank filler neck from the fuel tank.
6. Support the fuel tank.

Fuel Tank Shield:

7. Remove the fuel tank shield.

Fuel Tank:

8. Remove the tank straps.

NOTE:
- Ensure that the connections to both roll over valves are disconnected prior to lowering the fuel tank more than 51 mm (2 in). The roll over valves are located at both the front and rear of the fuel tank.
- Use extreme care when lowering the fuel tank. The fuel sender is made of plastic. Lowering the fuel tank may damage the fuel sender.

9. Lower the fuel tank.




10. Disconnect the fuel and vapor hoses and the electrical connections at the sender.




11. Use tool J 39765 in order to remove the fuel sender and the seal ring.
12. Discard the old seal ring.

INSTALLATION PROCEDURE




1. Install a new seal ring.

NOTE: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

2. Reinstall sender using tool J 39765.
3. Raise tank slightly.




4. Reconnect the fuel and vapor hoses and the electrical connections at the sender. Ensure the ground strap is also reinstalled to the body.
5. Raise the tank fully.




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

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 Service Precautions.

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.

Fuel Tank:

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

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

Fuel Tank Shield:

9. Install the fuel tank shield
10. Lower the vehicle.
11. Refill the fuel tank.
12. Reinstall fuel tank filler cap.
13. Reconnect the negative battery cable.
If a memory retention device was not used, reset (to the extent possible) all devices that lost memory after the battery was disconnected.
14. Check for leaks.