Fuel Tank Assembly

TOOLS REQUIRED
J 34730 Fuel Pressure Gauge
J 39765 Fuel Sender Lock Nut Wrench


CAUTION:
- Provide additional support when a vehicle is on a hoist:
- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

NOTICE:
- Do not attempt to straighten the kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.
- Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:

- The fuel pipe connections
- The hose connections
- The areas surrounding the connections

Description:

PROCEDURE
1. Relieve the fuel system fuel pressure.
2. Drain the fuel tank (4).
3. Raise the vehicle.
4. Remove the exhaust system.
5. Remove the wheel house filler pipe (1) opening cover in order to gain access to the fuel tank filler pipe.

Description:

6. Remove the fuel tank filler pipe attaching screws (5).
7. Remove the fuel tank filler pipe hose clamps and the fuel tank filler pipe.
8. Remove the fuel feed, fuel return, and vapor pipes near the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
9. Remove the [1][2]EVAP pipes and retainers at the evaporative emission canister.
10. Remove the rear tie rod ends.
11. Remove the rear suspension support assembly bolts and the lower suspension support assembly, refer to Rear Suspension.
2 12. Remove the fuel tank bolts (3) from the fuel tank (2) straps.
13. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.

DISASSEMBLE PROCEDURE
1. If the fuel tank is not being replaced, go to INSTALLATION PROCEDURE.
2. Disassemble the harness retaining straps (2).
3. Disassemble the fuel feed, fuel return, and [1][2]EVAP hoses.
4. Disassemble the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.

ASSEMBLE PROCEDURE
1. Assemble the fuel sender assembly.
2. Assemble the fuel feed, fuel return, and [1][2]EVAP hoses.
3. Assemble the harness retaining straps (2).
4. Assemble the fuel tank filler pipe and fuel tank filler pipe clamps.

INSTALLATION PROCEDURE
1. Position and support the fuel tank (4) with the aid of an assistant.
2. Install the fuel tank straps (2).
- Tighten the bolts to 48 N.m (35 lb. ft).
3. Install the rear suspension support assembly bolts and the lower suspension support assembly.
- Tighten the bolts to 165 N.m (122 lb. ft).
4. Install the rear tie rod ends.
5. Install the [1][2]EVAP pipes and retainers at the evaporative emission canister.
6. Install the fuel feed, fuel return, and vapor pipes near the fuel filter.
7. Install the fuel tank filler pipe hose clamps and the fuel tank filler pipe.
8. Install the fuel tank tiller pipe attaching screws (5).
9. Install the wheel house tiller pipe opening coven
10. Install the exhaust system.
11. Lower the vehicle.
12. Add fuel and install the fuel tank filler pipe (1) cap.
13. Install the negative battery cable.
14. Inspect for leaks.
14.1. Turn the ignition switch to the On position for 2 seconds.
14.2. Turn the ignition switch to the Off for 10 seconds.
14.3. Turn the ignition switch to the On position.
14.4. Check for fuel leaks.
15. Install the rear seat cushion.