2012 Jeep Wrangler JK Factory Service Manual 14 - Fuel System

TANK, Fuel

REMOVAL

REMOVAL

WARNING:

The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.


  1. Remove fuel fill cap.

    2.  
  2. Raise and support vehicle (Refer to 04 - Vehicle Quick Reference/Hoisting - Standard Procedure) .

    3.  
  3. Loosen the fuel fill hose clamp (2) at rear of tank (3) and disconnect fuel fill hose (1) from fuel tank.

    NOTE:

    There is a small flapper valve installed at the fuel tank filler opening.


    4.  
  4. Using an approved diesel fuel draining station, position a drain hose into the fuel fill hose opening and drain the fuel tank.

    5.  
  5. Disconnect quick-connect fittings (1) and (4) for fuel supply and return lines at front of tank.

    6.  
  6. Disconnect the quick-connect fittings (6) and (8) for fuel vapor and vent lines at rear of tank (Refer to 14 - Fuel System/Fuel Delivery/FITTING, Quick Connect/Standard Procedure) .

    7.  
  7. Remove the front transfercase skid plate bolts (2) and the rear bolts (3) and remove the transfercase skid plate (4).

    8.  
  8. Support fuel tank with a hydraulic jack.

    NOTE:

    The fuel tank skid plate and the fuel tank assembly are removed together. They share common fasteners.


    9.  
  9. Remove the two fuel tank mounting bolts at the front of fuel tank.

    10.  
  10. Remove the three tank mounting bolts at right side of fuel tank.

    11.  
  11. Remove the three tank mounting bolts at left side of fuel tank.

    12.  
  12. Partially lower tank to gain access to pump module electrical connector (4). Disconnect fuel pump module wire harness connector (4).

    13.  
  13. Continue lowering tank for removal.

    14.  
  14. Lift fuel tank from skid plate.

    15.  
  15. If the fuel pump module is to be replaced, remove fuel pump module from tank.

    16.  

INSTALLATION

INSTALLATION

  1. If fuel pump module had been removed, install module to tank.

    2.  
  2. Position fuel tank into skid plate.

    3.  
  3. Position the fuel tank assembly onto a hydraulic jack.

    4.  
  4. Partially raise the fuel tank to the body. Connect the pump module wire harness connector (4) to fuel pump module.

    5.  
  5. Continue raising the fuel tank snugly to body.

    6.  
  6. Install three tank mounting bolts at left side of fuel tank. Tighten to 61 N·m (45 ft. lbs.).

    7.  
  7. Install three tank mounting bolts at right side of fuel tank. Tighten to 61 N·m (45 ft. lbs.).

    8.  
  8. Install two tank mounting bolts at front of fuel tank. Tighten to 61 N·m (45 ft. lbs.).

    9.  
  9. Position the transfercase skid plate and install the rear transfer case skid plate (3) and the front bolts (2). Tighten to 65 N·m (48 ft. lbs.).

    10.  
  10. Connect the quick-connect fittings (6) and (8) for fuel vapor and vent lines at rear of tank.

    11.  
  11. Connect quick-connect fittings (1) and (4) for fuel supply and return lines at front of tank.

    12.  
  12. Connect fuel fill hose (1) at rear of tank (3) and tighten the fuel fill hose clamp (2).

    13.  
  13. Lower the vehicle.

    14.  
  14. Refill the fuel tank with the diesel fuel from the diesel fuel drain station.

    15.  
  15. Install fuel fill cap.

    16.