Fuel Tank Replacement EFI/MFI

Tools Required

J 36608 Fuel Sender Tool

1. Drain the fuel tank. Refer to Fuel Tank Draining .
2. 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.

3. Disconnect the vent hose at the fuel tank.
4. Disconnect the filler tube at the fuel tank.
5. Support the fuel tank.
6. With the aid of an assistant, remove the fuel tank strap attaching bolts (1,2), the nuts (5,6) and the fuel tank strap(s) (3) and the shield.
7. Lower the fuel tank enough to disconnect the fuel sender electrical connector and the retaining clips.
8. Disconnect the hoses from the fuel sender assembly.
9. Remove the fuel tank from the vehicle and place the tank in a suitable work area.
10. Remove the fuel sender assembly from the fuel tank using the J 36608 Fuel Sender Tool. Refer to Fuel Sender Assembly Replacement .

1. Install the fuel sender assembly with new O-rings on the fuel pipes. Refer to Fuel Sender Assembly Replacement .



2. Position and support the fuel tank.
3. Position the fuel tank strap(s) (3) and connect the fuel feed and return hoses to the fuel sender.
4. Connect the electrical connector to the fuel sender assembly.
5. Install the retaining clips.
6. Install the fuel filler vent hose to the vent pipe.
7. 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.

8. Install the fuel tank strap attaching bolts (1,2) and the nuts (5,6).

Tighten
Tighten the fuel tank strap bolts and nuts to 13 N·m (115 lb in).

9. Bleed any air from the fuel system. Refer to Fuel Feed Pipe and Return Pipe Purging .
10. Start the engine and check for leaks.