Fuel Tank Replacement P42
Removal Procedure
Tools Required
J 36608 Fuel Sender
Tool
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Raise the vehicle on a suitable hoist.
Important: Clean all the fuel pipe and hose connections as well as the surrounding
areas before disconnecting the fuel pipes and hoses.
- Disconnect the vent hose at the fuel tank.
- Disconnect the filler tube at the fuel tank.
- Support the fuel tank
(4).
- With the aid of an assistant, remove the fuel tank strap attaching
bolts (6), nuts (1) and the fuel tank straps (5) and shield.
- Lower the fuel tank enough to disconnect the fuel sender electrical
connector and the retaining clips.
- Disconnect the hoses from the fuel sender assembly.
- Remove the fuel tank from the vehicle and place the tank in a
suitable work area.
- Remove the fuel sender assembly from the fuel tank using the fuel
sender toolJ 36608
. Refer
to
Fuel Sender Assembly Replacement
.
Installation Procedure
- Install the fuel sender assembly with new O-rings on the fuel
pipes. Refer to
Fuel Sender Assembly Replacement
.
- Position and support the
fuel tank (4).
- Position the fuel tank straps (5) and connect the fuel feed and
return hoses to the fuel sender fittings.
- Connect the electrical connector to the fuel sender assembly.
- Install the retaining clips.
- Install the fuel filler vent hose to the vent pipe.
- Install the fuel filler neck connecting tube to the fuel tank.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the fuel
tank strap bolts (6) and nuts(1).
Tighten
Tighten the fuel tank strap bolts and nuts to 13 N·m (115 lb in).
- Bleed any air from the fuel system. Refer to
Fuel Feed Pipe and Return Pipe Purging
.
- Start the engine and check for leaks.
Fuel Tank Replacement P32
Removal Procedure
- Drain the fuel from the tank. Refer to
Fuel Tank Draining
.
- Raise the vehicle.
- Remove the fuel tank rear
shield, if equipped.
- Remove the fuel tank side
shield, if equipped.
- Support the fuel tank and remove the tank straps and insulator strips,
if equipped.
- Lower the fuel tank.
- Disconnect the fuel feed and vapor hoses.
- Disconnect the electrical connections at the sender.
- Remove the fuel sender assembly and seal ring, using tool J 39765
. Discard the old seal ring. Purge the
tank, if the tank is being repaired.
Installation Procedure
- Install the new seal ring and reinstall the sender using tool J 39765
.
- Raise the tank slightly and reconnect the fuel feed and vapor
hoses and the electrical connections at the sender.
- Raise the tank fully.
- Support the fuel tank and install the tank straps and the insulator
strips.
Notice: Tighten the strap fasteners by steps, alternating between the fasteners,
until the specified torque is reached. A failure to tighten the strap fasteners
as specified will cause the bottom of the tank to flex upward. This will result
in the fuel gauge indicating that there is fuel remaining in the tank when
the tank is empty.
- Install the fuel tank brackets with insulator strips in place.
Tighten
Tighten the strap nuts to 45 N·m (33 lb ft).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the rear fuel
tank shield.
- Install the fuel tank
side shield.
- Replenish the fuel in the tank. Reinstall the fuel tank filler
cap.
- Reconnect the negative battery cable. If a memory retention device
was not used, please reset (to the extent possible) all devices that lost
their memory after the battery was disconnected.
- Check for fuel leaks.
10.1. | Turn ON the ignition switch for 2 seconds. |
10.2. | Turn OFF the ignition switch for 10 seconds. |
10.3. | Again, turn the ignition switch to the ON position. |
10.4. | Check for fuel leaks. |