Fuel Tank Replacement 4 Door Utility

1. Drain the fuel from the fuel tank. Refer to Fuel Tank Draining Procedure .
2. Raise the vehicle. (This must be done with a frame hoist to allow the rear suspension to hang.)



3. Remove the filler hose and vent hose from the fuel tank.



4. Support the fuel tank and remove the fuel tank straps.



5. Lower the fuel tank shield and the fuel tank.



6. Disconnect the fuel feed (1) and vapor (2) hoses.
7. Disconnect the electrical connector at the sender.



8. Remove the fuel tank.



9. Remove the fuel sender and the seal ring. Discard the old seal ring.

1. Install the new seal ring and reinstall the sender.
2. Raise the tank and reconnect the electrical connector at the sender.



3. Reconnect the fuel feed and vapor hoses.



4. Raise the tank fully and reinstall the tank shield.




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. Reinstall the tank straps.

Tighten
Tighten the bolts to 35 N·m (47 lb ft).




6. Reinstall the filler hose and the vent hose to the tank.
7. Replenish the fuel. Reinstall the fuel tank filler cap.
8. Reconnect the negative battery cable.
9. Check for fuel leaks.

9.1.	Turn ON the ignition switch for 2 seconds.

9.2.	Turn OFF the ignition switch for 10 seconds.

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

9.4.	Check for fuel leaks.