REMOVAL & INSTALLATION
See Figure 1
- Disconnect the negative battery cable.
- Relieve the fuel system pressure. For details, please refer to the procedure located earlier in this section.
- Remove the fuel from the fuel tank by pumping it out through the filler neck using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011, or equivalent.
- Raise and safely support the vehicle, then disconnect and remove the fuel filler tube.
- Support the fuel tank, then remove the fuel tank support straps. Partially lower the fuel tank, then detach the fuel lines, electrical connectors and vent lines from the tank. Remove the fuel tank from the vehicle, then place it on a work bench. Remove any dirt around the fuel pump attaching flange, so it will not get into the fuel tank.
- Using Fuel Tank Sender Wrench D84P-9275-A or equivalent, turn the fuel pump lock ring counterclockwise, then remove the lock ring.
- Remove the fuel pump and bracket assembly from the fuel tank, then remove and discard the flange gasket.
- Clean the fuel pump mounting flange, as well as the fuel tank mounting surface and seal ring groove.
- Put a light coating of grease on the new seal gasket to hold it in place during assembly, then install the gasket in the fuel ring groove.
- Carefully install the fuel pump and sender assembly, making sure that the filter is not damaged. Make sure that the locating keys are in the keyways and that the seal ring stays in place.
- Hold the assembly in place, then install the lock ring finger-tight, making sure all locking tabs are under the tank lock ring tabs.
- Tighten the lock ring using Fuel Tank Sender Wrench D84P-9275-A or equivalent, by turning it clockwise until the ring is up against the stops.
- Remove the fuel tank from the bench and support the tank while attaching the fuel lines, vent lines and electrical connectors to their proper locations.
- Install the tank in the vehicle, then secure with the retaining straps. Carefully lower the vehicle.
- Install the filler tube and tighten the retaining screws.
- Fill the tank with at least 10 gallons of fuel, then check for leaks.
- Connect the negative battery cable.
- Connect a suitable fuel pressure gauge. Turn the ignition switch to the ON position 5-10 times, leaving it on for 3 seconds at a time, until the pressure gauge reads at least 30 psi (207 kPa). Check for leaks at the fittings.
- Remove the pressure gauge, then start the engine and recheck for leaks.
- Ground the fuel pump lead of the self-test connector through a jumper wire at the FP lead.
- Connect a suitable fuel pressure tester to the fuel pump outlet.
- Turn the ignition key to the RUN position to operate the fuel pump.
- The fuel pressure should be 35-45 psi (241-310 kPa) for the 3.0L and 3.8L engines. For the 2.5L engine, the fuel pressure should be 45-60 psi (310-414 kPa).
A safety inertia switch is installed to shut off the electric fuel pump in case of collision. The switch is located on the left-hand side (driver's side) of the car, behind the rearmost seat side trim panel, or inside the rear quarter shock tower access door. If the pump shuts off, or if the vehicle has been hit and will not start, check for leaks first, then reset the switch. The switch is reset by pushing down on the button provided.