Removal and Replacement
REMOVAL PROCEDURE1. Disconnect the negative battery cable.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
2. Remove the fuel filler pipe.
3. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure (2-Door Utility).
4. Raise the vehicle.
5. Remove the fuel tank front shield (4) (without underbody shield package).
6. Remove the fuel tank shield (4 wheel drive with underbody shield package).
7. Support the fuel tank.
8. Remove the fuel tank front strap (1).
NOTE: Ensure that the rollover valve connection and the fuel sender connections are disconnected prior to lowering the fuel tank more than 51 mm (2 in) in order to prevent damage to the fuel tank and the fuel sender.
9. Remove the fuel tank rear strap (4).
10. Disconnect the EVAP pipe from the rollover valve.
11. Carefully lower the fuel tank no more than 51 mm (2 in).
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. Disconnect the fuel pressure sensor and the fuel sender electrical connectors.
13. Disconnect the fuel feed pipe, the fuel return pipe, and the evaporative emission (EVAP) pipe at the fuel sender.
14. Remove the fuel tank from the vehicle.
15. 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.
7. Connect the EVAP pipe to the rollover valve.
8. Install the rear fuel tank strap (4) and the protector (2) to the crossmember with the bolt (3) and the retainer (1).
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.
Tighten
Tighten the fuel tank strap bolt to 18 N.m (13 lb ft).
9. Install the rear fuel tank strap to frame bolt (3).
Tighten
Tighten the fuel tank strap bolt to 18 N.m (13 lb ft).
10. Install the rear fuel tank shield (without underbody shield package).
11. Push the shield (2) onto the horizontal flange of the fuel tank (1).
12. The shield (2) is designed with interference to the bottom of the fuel tank (3).
13. Install the fuel tank front shield (4), washer (2), and nut (3) (without underbody shield package).
Tighten
Tighten the fuel tank shield nut to 25 N.m (18 lb ft).
14. Install the fuel tank shield to the fuel tank strap bolt (5) with the washer (3) and the nut (4) (4 wheel drive with underbody shield package).
15. Install the fuel tank shield to frame bolts (2).
Tighten
1. Tighten the fuel tank shield bolts (2) to 11 N.m (97 lb in).
2. Tighten the fuel tank shield nut (4) to 25 N.m (18 lb ft).
3. Install the fuel tank shield to crossmember bolts (1) and nuts (6).
Tighten
Tighten the fuel tank shield bolts and nuts to 23 N.m (17 lb ft).
4. Install the fuel filler pipe.
5. Lower the vehicle.
6. Refill the fuel tank.
7. Install the fuel tank filler cap.
8. Connect the negative battery cable.
9. Inspect for leaks.
9.1. Turn ON the ignition for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn ON the ignition.
9.4. Inspect for fuel leaks.