Fuel Tank Replacement (4-Door)

REMOVAL PROCEDURE




1. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure (Pick Up) or Fuel Tank Draining Procedure (2-Door Utility) or Fuel Tank Draining Procedure (4-Door Utility).
2. If applicable remove the fuel tank shield (2).




3. Loosen the fuel fill hose clamp (3) at the fuel tank (1).
4. Disconnect the lower fuel fill hose (2) from the fuel tank (1).
5. Disconnect the vent hoses from the fuel limiter vent valve.
6. Disconnect the vent hose from the rollover valve at the front of the fuel tank.




7. Disconnect the fuel pressure sensor and the fuel sender harness connectors (2 3) from the fuel sender (1).




8. Disconnect the fuel feed, return and EVAP purge pipes (2, 3, 4), at the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar).




9. Support the fuel tank.
10. Remove the fuel tank straps (1).
11. Remove the fuel tank and place it in a suitable work area.
12. 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.

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 is empty.

4. Install the fuel tank straps (1).

Tighten
^ Tighten the fuel tank strap nut (3) to 18 N.m (13 lb ft).
^ Tighten the fuel tan strap bolt (2) to 18 N.m (13 lb ft).




5. Connect the fuel feed, return and EVAP purge pipes (2, 3, 4) at the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar).




6. Connect the fuel pressure sensor and the fuel sender harness connectors (2, 3) to the fuel sender (1).
7. Connect the vent hose to the rollover valve at the front of the fuel tank.
8. Connect the vent hoses to the fuel limiter vent valve.




9. Connect the lower fuel fill hose (13) to the fuel tank and lower fuel fill tube (12).

Tighten
Tighten the fuel fill hose clamps (1, 2) to 2.5 N.m (22 lb in).




10. Install the fuel tank shield (2).

Tighten
Tighten the fuel tank shield bolts (3, 4) to 33 N.m (24 lb ft).

11. Lower the vehicle.
12. Remove the fuel till cap and refill the fuel tank.
13. Install the fuel tank filler cap.
14. Connect the negative battery cable.
15. Inspect for leaks using the following procedure:
15.1. Turn ON the ignition, with the engine OFF for 2 seconds.
15.2. Turn OFF the ignition, for 10 seconds.
15.3. Turn ON the ignition, with the engine OFF.
15.4. Inspect for fuel leaks