Fuel Tank Replacement (Rear Tank)
REMOVAL PROCEDURECAUTION: Refer to the Battery Disconnect Caution in Cautions And Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Lower and remove the under chassis mounted spare tire.
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove rear cross member that holds the spare tire.
6. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank).
7. Loosen the rear tank to front tank fuel fill hose clamp (3).
8. Disconnect the fuel fill hose (2) from the rear fuel tank.
9. Disconnect the rear chassis fuel pipe (2) at the fuel sender (1).
10. Disconnect the fuel sender electrical connectors.
11. Disconnect the Evaporative Emission (EVAP) pipes at the rear tank EVAP pipes (5).
12. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
13. With the aid of an assistant, support the fuel tank.
NOTE: Refer to Fuel Tank Straps Notice in Cautions and Notices.
14. Remove the fuel tank strap attaching bolts.
15. Remove the fuel tank straps.
16. Remove the fuel tank.
17. Place the fuel tank in a suitable work area.
18. Remove the EVAP pipes from the fuel tank roll over valves (1), (3) and the retaining clips (2).
19. Remove the fuel sender assembly from the fuel tank.
INSTALLATION PROCEDURE
1. Connect the EVAP pipe to the fuel tank roll over valves (1), (3) and the retaining clips (2).
2. Install the fuel sender assembly to the fuel tank.
NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the fuel fill hose to the fuel tank.
Tighten
Tighten the hose clamp to 2.5 N.m (22 lb in)
4. Install the fuel tank.
5. Install the fuel tank straps.
6. Install the fuel tank strap attaching bolts.
Tighten
Tighten the bolts to 40 N.m (30 lb ft).
7. Connect the fuel fill hose (2) to the rear fuel tank.
Tighten
Tighten the fuel fill hose clamp (3) to 2.5 N.m (22 lb in)
8. Connect the fuel fill pipe ground strap.
9. Connect the vent hose (3) to the vent pipe (1).
Tighten
Tighten the vent hose clamp (2) to 2.5 N.m (22 lb in)
10. Remove the caps from the fuel and EVAP pipes.
11. Connect the EVAP pipes at the rear fuel tank EVAP pipes (5).
12. Connect the fuel sender electrical connectors.
13. Connect the rear chassis fuel pipe (2) to the fuel sender (1).
14. Install the rear cross member that holds the spare tire.
15. Lower the vehicle.
16. Install and raise into position the under chassis mounted spare tire.
17. Refill the fuel tank.
18. Install the fuel filler cap.
19. Connect the negative battery cable.
20. Inspect for leaks.
20.1. Turn the ignition ON for 2 seconds.
20.2. Turn the ignition OFF for 10 seconds.
20.3. Turn the ignition ON.
20.4. Inspect for fuel leaks.