Install Fuel Tank Assembly
1. With aid of an assistant, position fuel tank under vehicle.2. Attach electrical connectors to fuel pump and tank pressure sensor.
NOTICE:
Position the fuel tank solidly against the left hand underbody side rail prior to tightening the strap mounting bolts. A small white locator button on the left side of the fuel tank shell should be tight against the left side rail at the completion of installation.
3. Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts (15 mm hex) to underbody.
Torque:
Fuel Tank Straps-to-Body: 47 Nm (35 ft-lbs)
4. Install (2) mounting screws (10 mm hex) for the fuel filter/pressure regulator bracket.
Torque:
Fuel Filter/Pressure Regulator-to-Frame
Rail: 8 Nm (71 in-lbs)
NOTICE:
Replace the plastic fuel line retainers whenever the fuel feed lines are disconnected at the fuel filter/pressure regulator and fuel rail. Install the new retainer into the female portion of the connection. Care must be taken to assure that the locking tab is centered in the window of the female connection. Firmly press the male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
5. Install a new retainer into the female portion of the 90° quick-connect fitting on the underbody fuel feed line.
IMPORTANT:
Lubricate the male ends of the fuel filter/pressure regulator with clean engine oil to ease installation.
6. Install the underbody fuel feed line onto the outlet of filter/regulator.
7. Ensure that the fuel filler check valve is in place at the end of the fuel filler pipe.
IMPORTANT:
To ease installation, lightly wipe the outside of the fuel tank inlet connector with plain water.
8. Position filler pipe into wheel opening with top of pipe within body panel opening.
9. Install fuel filler pipe into fuel tank opening.
10. Lower vehicle and move fuel filler pipe to rear of fuel door opening. Starting with front portion, install quarter panel grommet around fuel filler neck and work down through fuel door opening.
11. At location of upper fuel filler pipe attachment screw, pull just enough of quarter panel grommet out through fuel door opening and up over top of fuel filler pipe. Insert a flat blade tool inside fuel filler pipe between quarter panel grommet and fuel filler pipe edge to hold quarter panel grommet in place while installing upper attachment screw.
12. Raise vehicle and install fuel filler pipe lower bracket attachment bolt.
Torque:
Fuel Filler Pipe Lower Attachment
Bolt: 8 Nm (71 in-lbs)
13. Lower vehicle and install fuel filler pipe upper bracket attachment screw.
Torque:
Fuel Filler Pipe Upper Attachment
Screw: 4 Nm (35 in-lbs)
14. Carefully remove flat blade tool that was previously installed and route quarter panel grommet over top of fuel filler pipe.
15. Use a blunt end tool, such as a plastic tool, to carefully push remaining portion of quarter panel grommet under edge of fuel door opening as needed. Use care not to cut or damage quarter panel grommet.
16. Raise vehicle to a comfortable working height.
IMPORTANT:
Ensure fuel filler pipe connecting hose is installed to within 6 mm (1/4 in.) of the stops on fuel tank inlet neck. The hose clamp should be located within 4 mm (3/16 in.) of the end of connecting hose.
17. Tighten hose clamp (7 mm hex) on fuel filler pipe hose at fuel tank inlet neck.
Torque:
Fuel Filler Pipe Connecting Hose
Clamp: 4 Nm (35 in-lbs)
18. Connect wiring harness connector to EVAP canister vent solenoid.
19. Install driver's side rear wheelhouse liner to rear wheel opening.
20. Add fuel to fuel tank and install fuel filter cap.
21. Connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 Nm (13 ft.-lbs)
22. Prime fuel system using either of the following methods:
^ Cycle ignition switch On for 5 seconds and Off for 10 seconds. Repeat this twice.
^ Energize fuel pump using Scan tool. Run fuel pump for 10-20 seconds.
23. Examine all fuel line fittings that were disconnected for signs of leakage.
24. Start engine. Only crank engine for a maximum 15 seconds.
25. Using Scan tool perform the "[1][2]EVAP Service Bay Test." This test will verify the integrity of the vapor handling areas of fuel system. (Refer to SSS/Tech 2 User Guide for information on performing this test.)
^ If "[1][2]EVAP Service Bay Test" is PASSED, continue to next step.
^ If any [1][2]EVAP Service Bay Tests fail, refer to the appropriate DTC chart(s) in the Engine/Emission Controls section of the 2000/2001 S-Series Engine Service Manual.
- If "Vent Blockage" fails, refer to DTC P0446.
- If "Large Leak" fails, refer to DTC P0440.
- If "Purge Valve Leak" fails, refer to DTC P1441.
- If "System-Small Leak" fails, refer to DTC P0442.
26. Affix Campaign Completion Label on a clean and dry surface of radiator core support, in an area clearly visible when hood is raised. (For more information, refer to "CAMPAIGN COMPLETION LABEL" in this bulletin.)