Installation Procedure
- Place a NEW fuel pump module O-ring seal onto the fuel tank.
- Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
- Lower the module assembly into the tank.
- Install the module lock ring, and move it into position on the top of the module.
- Install the J 45722 to the lock ring .
- Using the J 45722 and a breaker bar, rotate the fuel pump module lock ring clockwise until the ring is locked into place on the fuel tank.
- Remove the J 45722 .
- Install the fuel feed line.
- Connect the fuel feed line quick connect fitting to the module. Refer to Plastic Collar Quick Connect Fitting Service .
- Install the fuel feed line to the retaining feature in the fuel tank.
- Install the electrical harness (1).
- Connect the fuel tank electrical harness connectors to the module and pressure sensor.
- Place the fuel tank onto the rear suspension crossmember.
- Install the fuel tank straps.
- Install the fuel tank strap bolts.
Tighten
Tighten the bolts to 46 N.m (34 lb ft).
- Install the rear coil springs while slowly raising the rear suspension crossmember using the adjustable jack (1).
- Install the rear suspension crossmember bolts.
Tighten
Tighten the bolts to 191 N.m (141 lb ft).
- Remove the adjustable jack from the rear suspension crossmember.
- Remove the jack stand from the front of the vehicle.
- Install the rear shock bolts.
Tighten
Tighten the bolts to 25 N.m (18 lb ft).
- Connect the body harness electrical connector to the fuel tank harness electrical connector (1).
- Install the fuel tank harness clips (2, 3) to the rear compartment side rail.
- Install the fuel and EVAP line retainer (1) to the side rail.
- Connect the fuel feed line quick connect fitting (1) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
- Connect the fill pipe vent line (2) and the fuel tank vapor line (3) quick connect fittings to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
- Install the left and right rear brake hose bracket studs into the keyhole slots. Tighten the nuts.
Tighten
Tighten the nut to 10 N.m (89 lb in).
- Install the exhaust system. Refer to Exhaust System Replacement .
- Connect the left and right electronic position sensor links to the ball studs (1). RPO F55 shown, F38 similar.
- Connect the automatic level control sensor link to the left rear suspension control arm, if equipped.
- Connect the fuel tank EVAP recirculation line quick connect fitting (1) to the fill pipe line. Refer to Plastic Collar Quick Connect Fitting Service .
- Connect the fuel fill hose (2) to the fuel fill pipe.
- Tighten the fuel fill hose clamp (1) at the fill pipe.
Tighten
Tighten the clamp to 4 N.m (35 lb in).
- Install the left rear wheel house liner. Refer to Rear Wheelhouse Panel Liner Replacement .
- Fill the fuel tank.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Perform the following procedure in order to inspect for leaks:
- Turn ON the ignition, with the engine OFF for 2 seconds.
- Turn OFF the ignition for 10 seconds.
- Turn ON the ignition, with the engine OFF.
- Inspect for fuel leaks.
- Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
the bucket must be slightly during installation to avoid bending the fuel level sensor float arm.
Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.
Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
Refer to Fastener Caution .
Clean the fill pipe or any dirt or debris. Ensure the fill pipe is installed to the original depth to the fill hose. The fill pipe bead must be inserted into the hose past the clamp position.