Removal Procedure
| • | J 39765 Fuel
Sender Lock Nut Wrench |
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to
the vehicle or its components.
- Disconnect
the negative battery cable.
- Drain the fuel from the tank. Refer to
Fuel Tank Draining
.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Loosen the fuel fill hose
clamp (2) and the vent hose clamp (3) at the fuel fill and vent pipe.
- Disconnect the fuel fill hose and the vent hose from the fuel
fill and vent pipe.
- Remove the fuel tank shield.
- Disconnect the fuel pressure
sensor and the fuel sender electrical connectors.
- Disconnect the fuel feed pipe, the fuel return pipe, and the EVAP
pipe at the fuel sender.
- Support the fuel tank.
- Remove the fuel tank straps (1,5).
Notice: Ensure that the connections to both roll over valves are disconnected
prior to lowering the fuel tank more than 51 mm (2 in). The
roll over valves are located at both the front and rear of the fuel tank.
- Disconnect the EVAP pipes from the rollover valves.
Notice: Use extreme care when lowering the fuel tank. The fuel sender is made
of plastic. Lowering the fuel tank may damage the fuel sender.
- Lower the fuel tank.
- Remove the fuel sender
from the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
Installation Procedure
- Install the fuel sender
into the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Install the fuel tank insulators.
- With the aid of an assistant,
position and support the fuel tank.
- Raise the fuel tank.
- Connect the EVAP pipes to the rollover valves.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
Important: When removing or replacing the fuel tank, the fuel tank support fasteners
should never be reused. Always use new fasteners when installing the fuel
tank.
- Install the fuel tank straps.
Tighten
| • | Tighten the fuel tank strap nut (3) to 18 N·m (13 lb ft.). |
| • | Tighten the fuel tank strap bolt (2) to 18 N·m (13 lb ft.). |
- Connect the fuel feed
pipe, the fuel return pipe, and the EVAP pipe at the fuel sender.
- Connect the fuel pressure sensor and the fuel sender electrical
connectors.
- Connect the fuel fill
hose and the vent hose to the fuel fill and vent pipe.
Tighten
| • | Tighten the fuel fill hose clamp (2) to 2.5 N·m (22 lb
in). |
| • | Tighten the vent hose clamp (3) to 1.7 N·m (15 lb
in). |
- Install the fuel tank
shield.
Tighten
Tighten the fuel tank shield bolts (2) to 33 N·m (24 lb
ft).
- Lower the vehicle.
- Refill the fuel tank.
- Install the fuel tank filler cap.
- Connect the negative battery cable.
- Inspect for leaks.
| 15.1. | Turn ON the ignition for 2 seconds. |
| 15.2. | Turn OFF the ignition for 10 seconds. |
| 15.3. | Turn ON the ignition. |
| 15.4. | Inspect for fuel leaks. |
