Fuel Tank Replacement (4-Door)

TOOLS REQUIRED
^ J 34730-1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

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.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.
4. Loosen the fuel fill hose clamp (2) and the vent hose clamp (3) at the fuel fill and vent pipe.
5. Disconnect the fuel fill hose and the vent hose from the fuel fill and vent pipe.




6. Remove the fuel tank shield.




7. Disconnect the fuel pressure sensor and the fuel sender electrical connectors.
8. Disconnect the fuel feed pipe, the fuel return pipe, and the [1][2]EVAP pipe at the fuel sender.




9. Support the fuel tank.
10. Remove the fuel tank straps (1,5).

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.

11. Disconnect the [1][2]EVAP pipes from the rollover valves.

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.

12. Lower the fuel tank.




13. 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 [1][2]EVAP pipes to the rollover valves.

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.

6. Install the fuel tank straps.

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




7. Connect the fuel feed pipe, the fuel return pipe, and the [1][2]EVAP pipe at the fuel sender.
8. Connect the fuel pressure sensor and the fuel sender electrical connectors.




9. Connect the fuel fill hose and the vent hose to the fuel fill and vent pipe.

Tighten
^ Tighten the fuel fill hose clamp (2) to 2.5 N.m (22 lb in).
^ Tighten the vent hose clamp (3) to 1.7 N.m (15 lb in).




10. Install the fuel tank shield.

Tighten
Tighten the fuel tank shield bolts (2) to 33 N.m (24 lb ft).

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.