Removal and Replacement

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 34730 - 1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

CAUTION: Provide additional support when a vehicle is on a hoist in the following ways:
^ 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.

CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Clean all the fuel pipe and fuel hose connections and surrounding areas before disconnecting the fuel pipes and the fuel hoses in order to avoid possible contamination of the fuel system.
5. Remove the fuel fill pipe housing bolts.
6. Raise the vehicle.




7. Disconnect the fuel fill pipe ground strap.




8. Remove the EVAP canister.




9. Disconnect the rear fuel return pipe and the rear fuel teed pipe at the chassis fuel pipes.
10. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.




11. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.




12. With the aid of an assistant support the fuel tank.

NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

13. Remove the fuel tank strap attaching bolts.
14. Remove the fuel tank straps.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.




17. Remove the fuel fill hose and pipe from the fuel tank.




18. Remove the fuel feed pipe (4) and the fuel return pipe (5) from the fuel sender (2) and the retaining clips (6).
19. Remove the EVAP pipe (1) from the fuel sender (2), the fuel tank roll over valve (3) and the retaining clips (6).




20. Remove the fuel sender assembly from the fuel tank.

INSTALLATION PROCEDURE




1. Install the fuel sender assembly to the fuel tank.




2. Connect the EVAP pipe (1) to the fuel sender (2), the fuel tank roll over valve (3) and the retaining clips (6).
3. Connect the fuel feed pipe (4) and the fuel return pipe (5) to the fuel sender (2) and the retaining clips (6).




4. Install the fuel fill hose and pipe to the fuel tank.

NOTE: Refer to the Fastener Notice in Service Precautions.

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




5. With the aid of an assistant, position and support the fuel tank.
6. Install the fuel tank straps.

NOTE: Refer to the Fastener Notice in Service Precautions.

7. Install the fuel tank strap attaching bolts.

Tighten
Tighten the fuel tank strap attaching bolts to 40 N.m (30 lb ft).




8. Connect the fuel sender and the fuel pressure sensor electrical connectors.




9. Remove the caps from the fuel and EVAP pipes.
10. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes.



11. Install the EVAP canister.




12. Connect the fuel fill pipe ground strap.




13. Install the fuel fill pipe housing bolts.

NOTE: Refer to the Fastener Notice in Service Precautions.

Tighten
Tighten the fuel fill pipe housing bolts to 2.3 N.m (20 lb in).

14. Refill the fuel tank.
15. Install the fuel filler cap.
16. Connect the negative battery cable.
17. Inspect for leaks.
17.1. Turn the ignition switch ON for 2 seconds.
17.2. Turn the ignition switch OFF for 10 seconds.
17.3. Turn the ignition switch ON.
17.4. Check for fuel leaks.
18. Perform a visual inspection of the fuel pipes in order to ensure that there is no kinking or misalignment of the fuel pipes.