Rendezvous 2006-2007

Removal & Installation

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NOTE
Always maintain cleanliness when servicing fuel system components.

  1. Relieve the fuel system fuel pressure.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Raise the vehicle.
  6.  
  7. Disconnect the fuel tank wiring harness connector at the body pass through.
  8.  
  9. For 3.4L engines, disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter.
  10.  
  11. For 3.4L engines, disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.
  12.  
  13. Disconnect the fuel tank evaporative emission (EVAP) pipe quick-connect fitting near the fuel filter.
  14.  
  15. Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer.
  16.  
  17. Remove the retaining nut for the EVAP canister bracket.
  18.  
  19. Loosen the fuel tank filler pipe hose clamp.
  20.  
  21. Disconnect the fuel tank filler pipe from the fuel tank.
  22.  
  23. For 3.5L engines, disconnect the EVAP vent pipe near the fill pipe hose.
    NOTE
    Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

  24.  
  25. With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts.
  26.  
  27. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
  28.  
  29. If the fuel tank is not being replaced, go to the Installation Procedure.
  30.  
  31. Disconnect the fuel tank wiring harness from the fuel sender assembly.
  32.  
  33. Remove the fuel sender shield from the fuel tank.
  34.  
  35. Disconnect the fuel feed and return pipe quick-connect fittings at the fuel sender.
  36.  
  37. Disconnect the EVAP vapor pipe assembly from the fuel sender.
  38.  
  39. Remove the fuel and/or EVAP pipe assembly from the fuel tank.
  40.  
  41. Remove the fuel sender assembly.
  42.  
  43. Remove the EVAP vent solenoid valve.
  44.  
  45. Remove the EVAP canister.
  46.  

To install:

  1. Install the EVAP canister.
  2.  
  3. Install the EVAP vent solenoid valve.
  4.  
  5. Install the fuel sender assembly.
  6.  
  7. Install the fuel and/or EVAP pipe assembly.
  8.  
  9. Connect the EVAP vapor pipe to the fuel sender assembly.
  10.  
  11. Connect the fuel feed and fuel return pipes at the fuel sender.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  12.  
  13. Install the fuel sender shield to the fuel tank and tighten the shield nuts to 53 inch lbs. (6 Nm).
  14.  
  15. Connect the fuel tank wiring harness to the fuel sender assembly.
  16.  
  17. With the aid of an assistant, position and support the fuel tank.
    NOTE
    Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

  18.  
  19. Install the fuel tank retaining strap attaching bolts and tighten the fuel tank retaining strap bolts to 35 ft. lbs. (47 Nm).
  20.  
  21. Install the EVAP canister retaining nut and tighten the retaining nut to 53 inch lbs. (6 Nm).
  22.  
  23. Connect the fuel tank filler pipe to the fuel tank and tighten the fuel tank filler pipe hose clamp to 22 inch lbs. (2.5 Nm).
  24.  
  25. Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
  26.  
  27. Connect the fuel return pipe quick-connect fitting near the fuel filter.
  28.  
  29. Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.
  30.  
  31. Connect the fuel tank wiring harness connector at the body pass-through.
  32.  
  33. Lower the vehicle.
  34.  
  35. Add fuel and reinstall the fuel tank filler pipe cap.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Inspect for fuel leaks with the following procedure:
    1. Turn ON the ignition for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  40.  

 
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