Removal and Replacement

REMOVAL PROCEDURE





TOOLS REQUIRED
J 34730 Fuel Pressure Gauge

CAUTION:
^ Provide additional support when a vehicle is on a hoist:
^ Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
^ Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

^ Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:
^ Use forced air ventilation such as a fan set outside of the trunk.
^ Plug or cap any fuel system openings in order to reduce fuel vapor formation.
^ Clean up any spilled fuel immediately.
^ Avoid sparks and any source of ignition.
^ Use signs to alert others in the work area that fuel system work is in process.

NOTE:
^ Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
^ The fuel pipe connections
^ The hose connections
^ The areas surrounding the connections
^ Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel teed or return pipes in order to prevent damage to the vehicle.

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief Procedure.
2. Drain the fuel tank (5). Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Cautions and Notices.

3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the exhaust system.




5. Remove the fuel tank filler pipe (2) from the grommet (1).
6. Remove the wheel house filler pipe opening cover.




7. Loosen the fuel tank filler pipe hose clamp (2) from the fuel tank filler pipe (1).




8. Disconnect the fuel feed (5), fuel return (6) quick connect pipes near the fuel filter.
9. Disconnect the [1][2]EVAP pipes (1), (2) at the evaporative emission canister.




10. Remove the rear tie rod ends.
11. Remove the rear suspension support assembly bolts and the lower suspension support assembly.
12. Remove the fuel tank bolts (4) from the fuel tank straps (2).
13. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.





DISASSEMBLE PROCEDURE
1. If the fuel tank is not being replaced, go to Installation Procedure.
2. Disassemble the harness retaining straps (2).
3. Disassemble the fuel feed, fuel return, and [1][2]EVAP hoses.
4. Disassemble the fuel sender assembly.





ASSEMBLE PROCEDURE
1. Assemble the fuel sender assembly.
2. Assemble the fuel feed, fuel return, and [1][2]EVAP hoses.
3. Assemble the harness retaining straps (2).

NOTE: Refer to Fastener Notice in Cautions and Notices.

4. Assemble the fuel tank filler pipe and fuel tank filler pipe clamp to the fuel tank.

Tighten
Tighten the clamp to 2.5 N.m (22 lb in).

INSTALLATION PROCEDURE




1. Position and support the fuel tank (4) with the aid of an assistant.
2. Reinstall the fuel tank straps (2).

Tighten
Tighten the fuel tank strap bolts (3). Tighten the bolts to 48 N.m (35 lb ft).

3. Reinstall the rear suspension support assembly bolts and the lower suspension support assembly.

Tighten
Tighten the suspension support assembly bolts to 165 N.m (122 lb ft).

4. Reinstall the rear tie rod ends.
5. Connect the [1][2]EVAP pipes and retainers at the evaporative emission canister.
6. Connect the fuel feed, fuel return, and vapor pipes near the fuel filter.
7. Tighten the fuel tank filler pipe hose clamp and the fuel tank filler pipe.

Tighten
Tighten the clamp to 2.5 N.m (22 lb in)




8. Reinstall the fuel tank filler pipe (2) into the grommet (1).




9. Reinstall the wheel house tiller pipe opening cover.
10. Reinstall the exhaust system.
11. Lower the vehicle.
12. Add fuel and reinstall the fuel tank filler pipe (1) cap.
13. Connect the negative battery cable.
14. Inspect for leaks.
14.1. Turn the ignition switch ON for 2 seconds.
14.2. Turn the ignition switch OFF for 10 seconds.
14.3. Turn the ignition switch On.
14.4. Check for fuel leaks.
15. Reinstall the rear seat cushion.
16. Install the intake manifold sight shield.

Tighten
Tighten the nuts to 3 N.m (27 lb in).