Fuel Tank

FUEL TANK

Part 1:

Part 2:

Part 3:

Exploded View

Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.

NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Disconnect the battery negative cable.
4. Remove the driveshaft.
5. Drain the fuel tank.







6. If equipped, remove the 4 bolts and the transfer case skid plate.
- To install, tighten to 40 Nm (30 lb-ft).

7. Disconnect the filler pipe vapor tube fitting.
8. Disconnect the fuel vapor vent valve-to-fuel pressure sensor and tube assembly hose.







9. Remove the bolts and the fuel filter heat shield.
- To install, tighten to 20 Nm (15 lb-ft).







10. Remove the nuts and the fuel filter shield.
- To install, tighten to 5 Nm (44 lb-in).

11. Disconnect the fuel filter spring lock coupling.
12. Disconnect the fuel pressure sensor and tube assembly-to-vapor tube fitting.
13. If equipped, remove the 3 bolts, 2 nuts and the fuel tank skid plate.
- To install, tighten to 40 Nm (30 lb-ft).







14. Using a suitable jack, support the fuel tank.
15. Remove the bolt and the fuel tank rear support strap.
- To install, tighten to 55 Nm (41 lb-ft).

16. Remove the nut and the fuel tank front support strap.
- To install, tighten to 55 Nm (41 lb-ft).

17. Lower the fuel tank far enough to access the fuel pump electrical connector and disconnect the connector.
18. Remove the fuel tank from the vehicle.
19. To install, reverse the removal procedure.