Installation

INSTALLATION PROCEDURE

IMPORTANT: Always install a new lip seal when servicing the modular fuel sender assembly.

1. Lightly lubricate the inside diameter of the lip seal with clean engine oil.






2. Install fuel sender assembly (1) into the fuel tank (4). Refer to Refer to Fuel Tank Unit / Service and Repair / Fuel Sender Assembly Replacement.

IMPORTANT: Assure proper location of fuel sender pipes.

3. Install fuel tank retaining straps (3) attaching bolts (2) with the aid of an assistant to the fuel tank (2).

4. Raise the fuel tank and connect [1][2]EVAP pipe.

- Tighten the fuel tank strap bolts to 34 N.m (25 lb. ft).

5. Install exhaust heat shield screws.

6. Connect the fuel sender electrical connector.






7. Install the fuel filler neck (2) and fuel filler neck vent pipe (1) at the fuel tank (4).

8. Install the clamps (3) at the fuel filler neck (2) and fuel filler neck vent pipe (1).

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






CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings in order to reduce the risk of fire and personal injury.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

9. Apply a few drops of clean engine oil to the male connector pipe ends.






10. Push connectors together to cause the retaining tabs/fingers to snap into place.






11. Pull on both ends of each connection to make sure connection is secure, once installed.

12. Lower the vehicle.

13. Connect the negative battery cable.

14. Add fuel to the fuel tank.






15. Install the fuel filler cap.

15.1. Turn ignition switch to ON for 2 seconds.

15.2. Turn the ignition switch to OFF for 5 seconds.

15.3. Turn the ignition switch ON.

15.4. Check for fuel leaks.