Fuel Tank Replacement (Short Wheelbase) (1)

Fuel Tank Replacement (Short Wheelbase) Single Use Fasteners and Components Fuel Sender Seal Special Tools CH–45722 Fuel Sender Lock Ring Wrench Equivalent regional tools: Special Tools

Drain the fuel tank. Fuel Tank Draining
Raise and support the vehicle. Lifting and Jacking the Vehicle

Fuel Tank Replacement (Short Wheelbase) (1) — figure 1

Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Remove [4x]
Remove both rear stabilizer shaft clamp (2) from the frame and let the stabilizer shaft hang.

Fuel Tank Replacement (Short Wheelbase) (1) — figure 2

Fuel Feed Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Return Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Tank Replacement (Short Wheelbase) (1) — figure 3

Fuel Tank Filler Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Filler Hose Clamp (2) » Loosen
Fuel Tank Filler Hose (3) » Remove

Fuel Tank Replacement (Short Wheelbase) (1) — figure 4

Place a suitable adjustable jack under the fuel tank.
Strap fuel tank to jack.
Fuel Tank Strap Bolt (1) » Remove [2x]
Fuel Tank Strap (2) » Remove [2x]

Fuel Tank Replacement (Short Wheelbase) (1) — figure 5

Lower the fuel tank, allowing clearance to access connections at the top of the tank.
Electrical Connector (1) » Disconnect
Fuel Feed Hose Clip (2) » Disengage
Wiring Harness Retainer (3) » Disengage
Retainer (4) » Unclip

Fuel Tank Replacement (Short Wheelbase) (1) — figure 6

Fuel Tank (1) » Remove
Remove the straps holding the fuel tank to the jack.
Remove the jack.

Fuel Tank Replacement (Short Wheelbase) (1) — figure 7

Fuel Tank Shield Retainer (1) » Remove [6x]
Fuel Tank Heat Shield (2) » Remove

Fuel Tank Replacement (Short Wheelbase) (1) — figure 8

Fuel Tank Filler Vent Hose (2) @ Evaporative Emission Canister Hose Clip (1) » Disengage
Fuel Tank Filler Vent Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Filler Vent Hose (2) » Remove

Fuel Tank Replacement (Short Wheelbase) (1) — figure 9

Tape (1) » Remove
Evaporative Emission Hose (4) @ Fuel Tank Vent Valve Hose Clip (2) » Disengage [2x]
Evaporative Emission Hose (4) @ Retainer (3) » Disengage
Evaporative Emission Hose (4) » Disconnect — Plastic Collar Quick Connect Fitting Service
Evaporative Emission Hose (4) » Remove

Fuel Tank Replacement (Short Wheelbase) (1) — figure 10

Fuel Return Hose (2) @ Evaporative Emission Canister Hose Clip (1) » Disengage [2x]
Fuel Return Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Return Hose (2) » Remove

Fuel Tank Replacement (Short Wheelbase) (1) — figure 11

Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Disengage [2x]
Fuel Feed Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Feed Hose (2) » Remove

Fuel Tank Replacement (Short Wheelbase) (1) — figure 12

Fuel Sender Retainer (1) » Remove — CH–45722 Fuel Sender Lock Ring Wrench(2)

Fuel Tank Replacement (Short Wheelbase) (1) — figure 13

Fuel Tank Fuel Pump Module (1) » Remove
Fuel Sender Seal (2) » Remove and DISCARD Installation Procedure
Fuel Sender Seal (2) » Install NEW
Fuel Tank Fuel Pump Module (1) » Install
Fuel Sender Retainer (1) » Install — CH–45722 Fuel Sender Lock Ring Wrench(2)
Fuel Feed Hose (2) » Install
Fuel Feed Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service
Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Engage [2x]
Fuel Return Hose (2) » Install
Fuel Return Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service
Fuel Return Hose (2) @ Evaporative Emission Canister Hose Clip (1) » Engage [2x]
Evaporative Emission Hose (4) » Install
Evaporative Emission Hose (4) » Connect — Plastic Collar Quick Connect Fitting Service
Evaporative Emission Hose (4) @ Retainer (3) » Engage
Evaporative Emission Hose (4) @ Fuel Tank Vent Valve Hose Clip (2) » Engage [2x]
Tape (1) » Install
Fuel Tank Filler Vent Hose (2) » Install
Fuel Tank Filler Vent Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Filler Vent Hose (2) @ Evaporative Emission Canister Hose Clip (1) » Engage
Fuel Tank Heat Shield (2) » Install
Fuel Tank Shield Retainer (1) » Install [6x]
Place a suitable adjustable jack under the fuel tank.
Strap fuel tank to jack.
Raise the fuel tank (1), allowing access to connections at the top of the tank.
Retainer (4) » Clip
Wiring Harness Retainer (3) » Engage
Fuel Feed Hose Clip (2) » Engage
Electrical Connector (1) » Connect
Raise the tank to the installed position.
Remove the straps holding the fuel tank to the jack.
Fuel Tank Strap (2) » Install [2x]

Fuel Tank Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications
Remove the jack.
Fuel Tank Filler Hose (3) » Install
Fuel Tank Filler Hose Clamp (2) » Tighten — Fastener Specifications
Fuel Tank Filler Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service
Fuel Return Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service
Fuel Feed Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service
Raise rear stabilizer shaft into installed position.
Rear Stabilizer Shaft Clamp (2) » Install [2x]
Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Install and tighten [4x] — Fastener Specifications
Lower the vehicle.
Refill the fuel tank.
Prime the fuel system and inspect for fuel leaks. Fuel System Priming