Removal Procedure
1. Remove the engine cover.2. Ensure that the fuel level in the fuel tank is less than 1/4 full. If necessary, drain the fuel level to no more than 1/4 full.
3. Relieve the fuel system pressure at the fuel rail service port.
a. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
b. Remove the fuel rail service port cap.
c. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve, catching the fluid in the towel.
d. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
e. Install the fuel rail service port cap.
f. Tighten the fuel fill cap.
WARNING
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present.
Do not allow smoking, the use of open flames or any ignition source in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required and have a dry chemical (Class B) fire extinguisher nearby.
WARNING
Fuel supply lines will remain pressurized for long periods of time after the engine is shut down. Fuel could spray out under pressure when you loosen or remove fuel lines. Opening a fuel system while it is under pressure may allow fuel to come in contact with an ignition source or with you causing personal injury.
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system.
NOTE:
Fuel will remain in the system after pressure is relieved. Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid. Never store fuel in an open container; due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
4. Record the radio presets and disconnect the negative battery cable.
5. Remove the muffler assembly.
a. Loosen the 2 exhaust pipe muffler clamps.
b. Disconnect the 5 rubber isolators from the exhaust pipe hangers.
c. Slide the muffler assembly from the exhaust pipes, removing it from the vehicle.
AWD Vehicles Proceed with step # 6. FWD vehicles continue to step # 7.
6. Remove the propeller shaft.
a. Place the transmission in neutral (N).
b. Mark the relationship of the propeller shaft to the rear differential drive flange and the transfer case flange.
c. Support the propeller shaft at the rear differential.
d. Remove the 4 mounting bolts for the propeller shaft at the rear differential drive flange.
e. Support propeller shaft at the transfer case.
f. Remove the 6 mounting bolts for the propeller shaft at the transfer case flange.
g. Support the propeller shaft at the center support bearing.
h. Remove the 2 mounting bolts for the center support bearing.
i. Remove the propeller shaft from the vehicle.
7. Disconnect the evaporative emission (EVAP) canister lines:
a. Fresh air hose.
b. Vent hose.
C. Chassis fuel feed line.
d. Electrical connector.
8. Disconnect connections at the fuel tank:
a. Fuel fill tube.
b. EVAP vent hose.
C. Fresh air hose.
d. Fuel tank electrical connector.
NOTE:
If present; remove the electrical connector retainer from the rear frame to allow disconnection of the electrical connector
9. Support the fuel tank and remove the 4 fuel tank strap bolts (2 each strap), and the 2 fuel tank straps.
NOTICE
The fuel tank straps can be easily bent.
Be careful not to damage the straps so that proper installation of the fuel tank can be completed.
10. With the help of an assistant if needed, lower the fuel tank and heat shield from the underbody of the vehicle and relocate to an area that will allow proper ventilation and cleanliness for the primary and secondary fuel tank module removal and replacement.
11. Remove the secondary fuel pump module.
a. Disconnect the EVAP vent line at the quick connect.
b. Using the required tool J39765-A, or equivalent (Secondary Fuel Sender Lock Ring Tool), remove the secondary fuel pump module lock ring.
NOTE:
Certain Driving Conditions will allow debris and dirt to accumulate on the Top of the Fuel Tank. Clean the area around the Primary and Secondary Fuel Pump Modules prior to removal)
NOTICE
Retainer rings can be easily damaged and rendered unfit for use.
To prevent Secondary module retainer ring damage, always use required tool J39765-A or equivalent (Secondary Fuel Sender Lock Ring Tool), and do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar or impact tools. Also, Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.
c. Disconnect the secondary level sensor electrical connector from the Secondary Fuel Pump Module
d. Disconnect the suction port attaching tube from the secondary module by pressing on the clip.
e. Remove the secondary fuel pump module.
f. Discard the fuel pump module-to-tank seal.
NOTICE
The sending unit float arm can be easily damaged during removal.
To prevent bending of the sending unit float arm during removal, lift the module up slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.
NOTE:
Always replace the fuel pump module-to-tank seal when the fuel pump module is removed.
12. Remove the primary fuel pump module.
a. Disconnect the electrical connectors from the primary fuel pump module and fuel tank pressure sensor.
b. Use required tool J 45722 or equivalent (Primary Fuel Sender Lock Ring Tool), and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.
NOTICE
Retainer rings can be easily damaged and rendered unfit for use.
To prevent primary retainer ring damage, always use required tool J45722 or equivalent (Primary Fuel Sender Lock Ring Tool), and do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar or impact tools. Also, Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.
c. Disconnect the fuel feed and vent lines from the fuel tank.
d. Remove the primary fuel pump module assembly.
e. Discard the fuel pump module-to-tank seal.
NOTICE
Retainer rings can be easily damaged and rendered unfit for use.
To prevent primary retainer ring damage, always use required tool J45722 or equivalent (Primary Fuel Sender Lock Ring Tool), and do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar or impact tools. Also, Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.
f. Take note of the suction port tube routing during the primary module removal and have a partner help route the tube to prevent damage.