REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Release the fuel system pressure using the recommended procedure.
- Remove the fuel pump unit through the access panel in the floor of the trunk. Drain the fuel tank into a portable fuel siphoning container through the opening in the fuel tank where the fuel pump is mounted.
Prior to disconnecting fuel lines, wrap a shop rag around the connections to absorb any fuel spillage due to residual pressure in the lines.
- Disconnect negative battery cable.
- Raise and safely support the vehicle. Remove both rear tires.
- Remove the exhaust pipe rubber insulators off the mounting studs of the rear of the vehicle and in front of the fuel tank.
- Using grease pencil or paint marker, place alignment marks on the fuel filler hose, filler tube, vent hose and vent tube.
- Remove the rear splash shield from the right rear wheel well.
- Disconnect the fuel filler hose and the vent hose near the fuel filter.
- Disconnect both ends of the sway bar from the stabilizer links. Use a grease pencil or paint marker to outline the position of the crossmember ends on the frame rail.
- Remove the crossmember mounting bolts and pull the crossmember down until it stops.
- Place a transmission jack under the fuel tank to support its weight.
The sway bar bracket bolts must be replaced after loosening or removal. Only use original equipment bolts as replacement.
- Remove the sway bar mounting bracket, heat shield and fuel tank strap. To prevent the sway bar from falling down, install sway bar mounting bracket with the bolts finger-tight only.
- Carefully and slowly lower the front of the fuel tank. Slide the tank away from the crossmember while pushing the filler vent and fill tube over the crossmember. Detach any remaining fuel or electrical connections. Lower the fuel tank.
- Position the tank on the transmission jack or other suitable lift, with the shield and the tank strap in place. Raise the tank over the crossmember and place it in the proper position. Be sure that the electrical connector, pressure relief/rollover valve hose, fuel supply and return lines are accessible through the opening in the trunk. Check to be sure that nothing is pinched or kinked in any way.
- Push the vent and the filler tube over the crossmember. Rotate the sway bar into position and install the sway bar brackets.
- Raise the tank into place and position the sway bar mounting bracket and the tank straps in place. Tighten the bolts to 44 ft. lbs. (60 Nm).
- Raise the crossmember into position and align with the locating marks made during removal. Install bolts and tighten to 70 ft. lbs. (95 Nm).
- Reconnect the filler tube and vent tube making sure to align with the marks made during removal.
- Connect the sway bar ends to the link arms and tighten sway bar mounting nuts to 74 ft. lbs. (100 Nm).
- Install the exhaust onto the hangers. Install the rear splash shield in the right rear wheel well.
- Install the rear wheels and lug nuts. Tighten the lug nuts, in a star pattern sequence, to 95-100 ft. lbs. (129-135 Nm).
- Lower the vehicle.
- Install the fuel pump module.
- Connect the fuel supply, return and vent tubes. After installation of the quick-connect fittings, check for proper connection by pulling back on the quick-connect fitting. The tube should lock in place. If the connection is not complete, make sure the black plastic ring is not causing the locking retainer to jam in the release position.
- Install the fuel pump access cover and gasket. Tighten the fasteners and install the trunk liner.
- Install the filler cap and reconnect the negative battery cable.
- With the ignition in the ON position, access the DRB III ASD Fuel System Test to pressurize the fuel system. Check for leaks.
- Check the rear wheel alignment and adjust, if necessary.
SENDING UNIT REPLACEMENT
See Figures 4, 5, 6, 7, 8, 9 and 10
- Release the fuel system pressure.
- Disconnect the negative battery cable.
- Remove the fuel pump module as described earlier in this section.
- Depress the retaining tab and remove the fuel pump sending unit connector from the bottom of the pump electrical connector.
- Remove the wire terminal retaining clip from the connector. Tag the location for the terminals of the sending unit wires.
- Using special tool 7812 or equivalent, push the sending unit signal and ground terminals out of the connector.
- Insert a flat bladed tool between the fuel pump module and the top of the sending unit housing. Push the sending unit down slightly.
- Slide the sending unit wires through the standpipe inside the pump module.
- Slide the sending unit out of the installation channel.
- Insert the sending unit wires in the bottom of the standpipe.
- Wrap the wires into the groove in the back of the sending unit.
- While feeding the wires into the standpipe, slide the sending unit up into the installation channel until it snaps into place. Ensure the tab at the bottom of the sending unit locks in place.
- Install the sending unit wires in the connector. Push the wires up through the connector and pull them down until they lock in place. Check the signal and ground wires to ensure they are installed in the correct position.
- Install the retaining clip on the connector.
- Push the sending unit connector up into the bottom of the pump module electrical connector.
- Install the fuel pump module. Refer to the procedure earlier in this section.
- Connect the negative battery cable.