B. Bend Fuel Tank Flange
1. Remove the fuel filler cap.
2. Release fuel pressure:
FOR 3.3L EQUIPPED VEHICLES:
WARNING:
The 3.3L MPI fuel system is under a constant pressure of approximately 48 psi (330 kpa).
a. Remove the protective cap from the fuel pressure test port on the fuel rail (Figure 2).
b. Place the open end of fuel pressure release hose (C-4799-1) into an appropriate container. Connect the other end of the hose to the fuel pressure test port. Fuel pressure will bleed off through the hose into the container.
c. Remove the hose and replace the fuel rail cap.
FOR 3.0L EQUIPPED VEHICLES:
a. Disconnect fuel rail wiring harness from engine harness.
b. Connect a jumper wire from the A142 circuit terminal of the fuel rail harness connector to the battery positive terminal (Figure 3).
c. Connect one end of a jumper wire to a good ground.
d. Momentarily ground one of the injectors by connecting the other end of the jumper wire to an injector terminal in the harness connector. Repeat for 2 to 3 injectors.
e. Remove the jumper wires and connect fuel rail wiring harness to engine harness.
3. Disconnect negative battery cable.
4. Raise vehicle on hoist.
5. Remove the rubber cap from the fuel tank drain tube (Figure 4). The tube is located on the rear of the fuel tank. Connect a portable holding tank or a properly labeled gasoline safety container to the drain tube and drain the fuel tank.
6. Remove screws that hold filler tube to inner and outer quarter panel (Figure 5).
7. Remove the left rear tire and wheel assembly.
8. Remove the left rear inner fender shield.
9. Remove the spring deflector shield.
10. Remove the screws (4) from the park brake cable adjustor bracket.
11. Disconnect fuel pump/level unit electrical connector.
12. Remove any loose dirt from fuel hose quick connect fittings.
WARNING:
Wrap shop towels around hoses to catch any gasoline spillage.
13. Remove both quick connect fittings from the fuel tubes by pushing in on the plastic ring located on the end of each fitting. Gently pull each fitting from the fuel tube. To aid in disassembly, an open end wrench may be used to push the plastic ring in.
14. Cover the quick connector to prevent contamination.
15. Use a transmission jack to support the fuel tank. Remove the bolts from the fuel tank straps.
16. Lower the tank slightly. Remove filler tube from tank.
17. Lower fuel tank. Disconnect pressure relief/rollover valve hose.
18. Remove clamp and remove fuel filler tube vent hose.
19. Remove fuel tank from the vehicle.
20. Place fuel tank on floor or other suitable surface.
21. Using duckbill pliers or vice grips and two flat metal plates (1/4" x 6" shim stock for the fuel hoses and 1/4"x 2" shim stock for the support straps), bend the fuel tank flange to 90 degrees as shown in Figure 6.
22. Position the fuel tank on transmission jack.
23. Connect pressure relief/rollover valve hose.
24. Connect fuel filler tube vent hose and clamp.
25. If flange was bent at either fuel tank strap location in Step B-21, new fuel tank strap(s) (PN 4279691) must be installed. Raise tank into position and carefully work fuel filler tube into tank. A light coating of transmission fluid on the tube end may be used to aid assembly.
26. Tighten the fuel tank strap bolts to 40 ft.lbs. (54 N-m). Remove the transmission jack.
CAUTION:
Ensure straps are not twisted or bent before tightening strap bolts.
27. Connect fuel pump/level unit electrical connector.
28. Inspect the fuel hoses for wear due to contact with the fuel tank flange. If the outer hose cover has been worn through so that the hose reinforcement cords are visible, replace the affected hose (Supply hose -- PN 4418951, Return Hose -- PN 4418952, 25 foot roll of Vapor Vent Hose -- PN 4443175).
29. Lubricate the metal tubes on the fuel pump with clean 30 weight engine oil.
30. Insert quick connect fitting onto fuel tube nipple. Push the fitting on until a "click" is heard, then pull back on the quick connect fitting to verify the connection is secure. The tube should be locked in place. If the hose will not lock on to the tube, pull back on the black plastic release of the quick connect fitting to ensure that it is in the locked position (not compressed). If the connection does not hold, replace the fuel hose.
31. Attach the park brake cable adjustor bracket.
32. Install the spring deflector shield.
33. Install the inner fender shield.
34. Install the left rear tire and torque wheel lug nuts to 95 ft.lbs. (130 N-m).
35. Attach filler tube to filler neck opening in quarter panel. Tighten quarter panel screws to 17 in.lbs. (1.9 N-m) (Figure 5).
36. Install cap on fuel tank drain tube and clamp.
37. Lower the vehicle.
38. Refill fuel tank and replace fuel filler cap.
39. Connect negative battery cable.
40. Start engine and check for fuel leaks.