6000 All Wheel Drive
Fuel Tank Removal (AWD):
CAUTION: If nylon fuel feed or return lines become kinked, and cannot be straightened, they must be replaced.
REMOVAL:
1. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL PRESSURE RELIEF.
2. Drain the fuel tank, refer to MAINTENANCE PROCEDURES/FUEL TANK DRAINING.
3. Raise the vehicle on a hoist.
4. Remove the rear section of the propeller shaft from the axle flange.
5. Remove the exhaust pipe and muffler from the catalytic converter and rear retainer/insulator.
- Clean all fuel pipe and hose connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.
6. Disconnect the filler tube and clamp from the fuel tank.
7. Remove the fuel vent tube and clamp from the fuel tank.
8. Disconnect the electrical connector.
9. Remove the vapor connecting hose and clamp from the liquid/vapor separator tank.
10. Disconnect the fuel feed line from the fuel filter.
11. Remove the fuel return line from the rear return line near the fuel filter.
CAUTION: DO NOT bend the fuel tank retaining straps, as this may damage the straps.
12. With the aid of an assistant, support the fuel tank and remove the front fuel tank retaining strap attaching bolts, and rear fuel tank strap attaching nuts and bolts, both fuel tank retaining straps and fuel tank.
- Check the fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.
FUEL LEVEL METER ASSEMBLY REPLACEMENT:
REMOVAL:
1. Remove the secondary fuel level meter assembly electrical connector from the fuel level meter assembly connector.
2. Remove the main electrical connector mounting clips and tape from the fuel tank and bushing.
3. Disconnect the fuel feed pipe assembly from the fuel level meter.
4. Remove the fuel return connecting hose, clamp and strap from the fuel level meter return tube.
5. Remove vapor connecting hose and clamp from the fuel level meter.
NOTE: Clean all fuel pipe and hose connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.
6. Using J 33431 or J 35731, remove the fuel level meter assembly retaining cam, fuel level meter assembly, and O-ring from the fuel tank. Discard the O-ring.
7. Clean the fuel level meter assembly sealing surfaces.
INSTALLATION:
1. Position a new fuel level meter assembly O-ring on the fuel tank.
- Care should be taken not to fold over or twist the fuel pump filter when installing the fuel level meter assembly as this will restrict the flow of fuel. Also, assure that the fuel pump filter does not block full travel of the float arm.
2. Install the fuel level meter assembly and fuel level assembly retainer cam using J 33431 or J 35731.
3. Install new main electrical connector mounting clips to the fuel tank.
- Tape the main electrical harness to the bushing and the fuel tank.
4. Connect the secondary fuel level meter electrical connector to the fuel level meter electrical connector.
5. Connect the fuel feed pipe assembly to the fuel level meter, and tighten the fittings to 27 Nm (20 lb.ft).
6. Connect the fuel return connecting hose and clamp to the fuel level meter vapor tube.
7. Connect the vapor connecting hose and clamp to the fuel level meter vapor tube.
8. Proceed to fuel tank installation.
SECONDARY FUEL LEVEL METER ASSEMBLY REPLACEMENT
Secondary Fuel Level Meter Location (AWD):
REMOVAL:
1. Remove the fuel tank using the above procedure.
2. Remove the rear fuel return pipe assembly.
3. Remove the fuel return connecting hose and clamp.
4. Remove the vapor connecting hose and clamp.
5. Disconnect the sensor electrical connector.
- Clean all fuel pipe and hose connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.
6. Using J 35731 remove the secondary fuel level meter assembly retaining cam, secondary fuel level meter assembly and O-ring from the right side of the fuel tank. Discard the O-ring.
7. Clean the secondary fuel level meter assembly sealing surfaces.
INSTALLATION:
1. Position a new secondary fuel level meter assembly O-ring on the right side of the fuel tank.
CAUTION: Care should be taken not to fold over or twist the scavenger fuel pump filter when installing the secondary fuel level meter assembly as this will restrict the fuel flow. Also, assure that the scavenger fuel pump filter does not block the full travel of the float arm.
2. Install the secondary fuel level meter assembly and secondary fuel level meter assembly retainer cam using J35731.
3. Connect the sensor electrical connection.
4. Install the vapor connecting hose and clamp.
5. Install the fuel return connecting hose and clamp.
6. Install the rear fuel return pipe assembly.
7. Install the fuel tank as described below.
LIQUID/VAPOR SEPARATOR TANK REPLACEMENT
Tank Liquid/Vapor Separator (AWD):
REMOVAL:
1. Remove the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
2. Remove the rear axle (module) assembly.
3. Remove the vapor hoses and clamps from the separator tank.
4. Remove the separator tank attaching screws and separator tank.
INSTALLATION:
1. Install the separator tank and the separator tank attaching screws, and tighten to 4 0 Nm (36 lb.in).
2. Install the vapor hoses and clamps to the separator tank.
3. Install the rear axle (module) assembly.
4. Tighten the fuel filler cap.
5. Connect the negative battery cable.
6. The ECM must relearn the ISC valve pintle position, refer to MAINTENANCE PROCEDURES/IDLE LEARN PROCEDURE.
FUEL TANK INSTALLATION
NOTE: Refer to the fuel tank image for the placement of the fuel tank insulators.
1. Install the insulator pads on the fuel tank and spacers on the front fuel tank strap mounting brackets in the same location as noted during disassembly.
2. Install the secondary fuel level meter assembly, if removed.
3. Install the fuel level meter assembly, if removed.
4. Install the fuel lines connecting the secondary fuel level meter assembly to the main fuel level meter assembly.
5. With the aid of an assistant, position and support the fuel tank. Install the fuel tank restraining straps, front attaching bolts and rear attaching bolts and nuts. Tighten the front fuel tank retaining strap bolts to 31 Nm (22 lb.ft), and the rear fuel tank retaining strap nuts to 12 Nm (108 lb.in).
6. Install fuel return line to the rear return line near the in-line fuel filter.
7. Connect the fuel feed line to the in-line filter and tighten the fittings to 27 Nm (20 lb.ft).
8. Connect the vapor connecting hose and clamp to the liquid/vapor separator tank.
9. Connect the fuel tank vent tube and clamp to the fuel tank.
10. Connect the fuel filler tube and clamp to the fuel tank.
11. Connect the electrical connector.
12. Install the exhaust pipe and muffler to the rear retainer/insulator and to the catalytic converter.
13. Install the rear section of the propeller shaft to the axle flange.
14. Lower the vehicle.
15. Add fuel and install the fuel filler cap.
16. Connect the negative battery cable.
17. Turn the ignition switch to the ON position for two seconds, then to the OFF position for ten seconds. Again turn to the ON position and check for fuel leaks.
18. The ECM will need to relearn the IAC valve pintle position following battery reconnect, refer to MAINTENANCE PROCEDURES/ IDLE LEARN PROCEDURE.