Fuel Tank Replacement P32

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
3. Raise the vehicle.



4. Remove the fuel tank rear shield, if equipped.



5. Remove the fuel tank side shield, if equipped.



6. Support the fuel tank and remove the tank straps and insulator strips, if equipped.



7. With the aid of an assistant, lower the fuel tank.
8. Disconnect the fuel feed and vapor hoses.
9. Disconnect the electrical connections at the sender.



10. Remove the retaining ring nuts (2). Remove the retaining ring (1) and the fuel sender assembly (3) . Discard the old seal ring. Purge the tank, if the tank is being repaired.

1. Reinstall the fuel sender (3) and a new seal ring. Install the retaining ring (1) and the retaining ring nuts (2).
2. Raise the tank under the vehicle to allow reconnection of the hoses and electrical connectors. Reconnect the fuel feed and vapor hoses and the electrical connections at the sender.



3. Raise the tank fully.




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.

4. Support the fuel tank and install the tank straps with the insulator strips in place.

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.

5. 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.




6. Install the rear fuel tank shield.



7. Install the fuel tank side shield.
8. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
9. 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.
10. 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.

Fuel Tank Replacement P42

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
3. Raise the vehicle.



4. Remove the fuel tank off-road shield, if equipped.

Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.




5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.



6. With the aid of an assistant, lower the fuel tank.
7. Disconnect the fuel feed and vapor hoses.
8. Disconnect the electrical connections at the sender.



9. Remove the retaining ring nuts (2) and the retaining ring (1). Remove fuel sender assembly (3). Discard the old seal ring. Purge the tank, if the tank is being repaired.

1. Install the new seal ring and the fuel sender (3). Install the retaining ring (1) and the retaining ring fasteners (2).
2. Raise the tank under the vehicle to allow for reconnection of the hoses and electrical connectors. Reconnect the fuel feed and vapor hoses and the electrical connections at the sender.



3. Raise the tank fully.

Reinstall the fuel tank filler neck to the tank. Tighten the clamp.





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.

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.

4. 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.




5. Install the fuel tank off-road shield, if equipped.
6. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
7. 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.
8. Check for fuel leaks.

8.1.	Turn ON the ignition switch for 2 seconds.

8.2.	Turn OFF the ignition switch for 10 seconds.

8.3.	Again, turn the ignition switch to the ON position.

8.4.	Check for fuel leaks.