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Home >> Jeep >> 2005 >> Wrangler Rubicon, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 520 (Fuel System) >> Fuel Delivery - 2.4L/3.7L Gas >> Fuel Tank >> Installation

Fuel Tank: Installation

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
  1. If fuel tank is to be replaced, install NVLD pump and fuel pump module to tank. Refer to FUEL PUMP MODULE .
  2. Position fuel tank to hydraulic jack.
    Fig 1: FUEL DELIVERY COMPONENTS
    GC0025627Courtesy of DAIMLERCHRYSLER CORP.
    1 - FUEL PUMP MODULE LOCK RING 4 - EVAP CANISTER
    2 - FUEL PUMP MODULE 5 - NVLD PUMP
    3 - ISOLATOR SLEEVE 6 - FUEL TANK
  3. Raise tank while carefully guiding vent tubes/hoses through isolator sleeve (3) and crossmember. See Fig 1.
  4. Continue raising tank until positioned to body.
    Fig 2: FUEL TANK MOUNTING
    GC0025652Courtesy of DAIMLERCHRYSLER CORP.
    1 - FILL FITTING
    2 - FUEL TANK
    3 - TANK MOUNTING BOLTS
    4 - TANK MOUNTING STRAPS
  5. Attach two fuel tank mounting straps (4) and four mounting bolts (3). Tighten bolts to 61 N.m (45 ft. lbs.) torque. See Fig 2.
    Fig 3: FUEL TANK VALVES
    GC0025628Courtesy of DAIMLERCHRYSLER CORP.
    1 - FUEL TANK 10 - FUEL TANK STRAPS
    2 - FUEL PUMP MODULE LOCK RING 11 - HEAT SHIELD
    3 - FUEL PUMP MODULE ASSEMBLY 12 - CHECK (CONTROL) VALVE
    4 - FLOW MANAGEMENT VALVE -
    5 - FUEL FILL TUBE -
    6 - FRESH AIR TUBE -
    7 - FUEL FILL HOSE -
    8 - FRESH AIR FILTER -
    9 - NVLD PUMP
  6. Connect electrical connector to NVLD pump (9). See Fig 3.
  7. Connect fresh air (6) and recirculation lines to fuel fill tube.
  8. Connect electrical connector to fuel pump module.
  9. Connect fuel line quick-connect fitting.
    Fig 4: FUEL FILL HOSE AT TANK
    GC0025649Courtesy of DAIMLERCHRYSLER CORP.
    1 - FUEL FILL HOSE AT TANK
    2 - HOSE CLAMP
    3 - WHITE PAINTED INDEX MARK
    4 - ALIGNMENT NOTCHES
    5 - LEFT SIDE OF FUEL TANK
    6 - FUEL FILL FITTING
  10. Install fuel fill hose and hose clamp to fuel tank fitting. Rotate hose until white painted index mark (3) on hose is located between alignment notches (4) on fuel tank fitting. Tighten clamp to 3.4 N.m (30 in. lbs.) torque. See Fig 4.
  11. If equipped, install fuel tank skid plate, trailer hitch and tow hooks. Refer to Tow Hooks, Trailer Hitch or Skid Plate in INTERIOR/EXTERIOR for removal/installation procedures.
  12. Lower vehicle.
  13. Connect negative battery cable to battery.
  14. Fill fuel tank with fuel.
  15. Start engine and check for fuel leaks.
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