Fuel Tank Replacement (2 Door)

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure (Pick Up) or Fuel Tank Draining Procedure (2-Door Utility).
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Remove the left rear splash shield.
5. Loosen the fuel fill hose clamp (2) and the vent hose clamp (1) at the fuel tank.
6. Disconnect the fuel fill hose and the vent hose from the fuel tank.




7. Remove the fuel tank shield.




8. Support the fuel tank.
9. Remove the fuel tank straps.

NOTE: Use extreme care when lowering the fuel tank. The fuel sender is made of plastic. Lowering the fuel tank may damage the fuel sender.

10. Lower the fuel tank.




11. Disconnect the fuel pressure sensor and the fuel sender electrical connectors.
12. Disconnect the fuel feed pipe, the fuel return pipe, and the evaporative emission (EVAP) pipe at the fuel sender.
13. Remove the fuel tank from the vehicle.




14. Remove the fuel sender from the fuel tank.

INSTALLATION PROCEDURE




1. Install the fuel sender into the fuel tank.




2. Install the fuel tank insulators.




3. With the aid of an assistant, position and support the fuel tank.
4. Raise the fuel tank.
5. Connect the fuel feed pipe, the fuel return pipe, and the EVAP pipe at the fuel sender
6. Connect the fuel pressure sensor and the fuel sender electrical connectors.

NOTE: 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.




7. Install the fuel tank straps.

Tighten
Tighten the fuel tank strap nuts to 91 N.m (67 lb ft).




8. Connect the fuel fill hose (2) and the vent hose (1) to the fuel tank.

Tighten
^ Tighten the fuel fill hose clamp to 2.5 N.m (22 lb in).
^ Tighten the vent hose clamp to 1.7 N.m (15 lb in).

9. Install the left splash shield.




10. Install the fuel tank shield.

Tighten
Tighten the fuel tank shield bolts to 11 N.m (97 lb in).

11. Lower the vehicle.
12. Refill the fuel tank.
13. Install the fuel tank filler cap.
14. Connect the negative battery cable.
15. Inspect for leaks.
15.1. Turn ON the ignition for 2 seconds.
15.2. Turn OFF the ignition for 10 seconds.
15.3. Turn ON the ignition.
15.4. Inspect for fuel leaks.