Dismantling
1. Disconnect "negative" battery terminal.
WARNING: Fuel vapors are highly flammable and in an enclosed area are also toxic and explosive. When working with fuel, it is necessary to have a foam type, carbon dioxide fire extinguisher at hand (CO2), gas or powder.
2. If the fuel tank is full, use the fuel recovery equipment to drain excess fuel through the fuel tank filler neck to a level below the height of the fuel pump.
3. Open the rear right door and cargo area door.
4. Fold the rear seat forward.
5. Remove the front and rear carpet fasteners.
6. Move the carpet away from the fuel tank gauge access hatch.
7. Remove the 6 screws securing the fuel meter access hatch cover to the floor.
8. Remove the fuel gauge access hatch cover.
9. Disconnect the connector block from the fuel level meter.
10. Place a container under the fuel tank to collect any fuel spills.
11. Loosen and remove the unloader valve, pressure line and return pipes from the meter body.
CAUTION: Fuel leakage is inevitable during this operation. Take safety precautions to prevent fire or explosion.
12. For vehicles with auxiliary heater (FBH): Loosen the clamp and disconnect the FBH fuel inlet pipe from the meter body.
CAUTION: Always plug fittings and openings to keep dirt out of the system.
13. Using tool LRT-19-009, remove the lock ring from the fuel tank body.
14. Remove the gauge housing from the fuel tank and discard the seal.
NOTE: The fuel pump and fuel gauge are integral parts of the fuel pump housing and cannot be replaced individually.
Installation
1. Clean the meter housing and mating surfaces.
2. Install a new gauge seal in the fuel tank.
3. Install a fuel gauge in the fuel tank.
4. Using tool LRT-19-009, install and secure the lock ring on the fuel tank housings.
5. Models with auxiliary heater FBH: Put the preheater delivery hose on the fuel pump fitting and secure with a clamp.
6. Install and fasten the pipes of the unloading valve, pressure line and return pipe to the fitting of the fuel pump housing and the meter.
7. Remove the container from under the fuel tank.
8. Connect the connector block to the fuel level meter.
9. Replace the manhole cover for access to the fuel pump and gauge and secure it with screws.
10. Replace carpeting and secure.
11. Set the rear seat to its original position.
12. Close the tailgate and cargo area door.
13. Attach "negative" battery terminal.
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