Removal & Installation (Catera - 3.0L)
CAUTION:
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
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.
- Raise and suitably support the vehicle. Remove the right hand rear fascia bolts. Remove the rear frame support.
- Disconnect the fuel feed line at the fuel filter and the return line near the fuel filter. Remove clamps from the fuel tank breather hose and EVAP hoses at the fuel tank near the fuel filter.
- Disconnect the fuel tank breather hose and the EVAP hoses. Remove the fuel sender electrical connector retainer. Disconnect the fuel sender electrical connector. Remove the fuel filter retaining bolt from the bracket. Remove the EVAP vent valve retaining bolt from the bracket.
- With the aid of an assistant, support the fuel tank. Remove the fuel tank retaining strap attaching bolts. Remove both fuel tank retaining straps. Lower the fuel tank.
- Disconnect the electrical connectors from the fuel tank pressure sensor (6) and the fuel tank connection cover (2). See Fig 1. Remove the fuel pressure (5) and return lines (1) from the tank connection cover and discard the clamps. Remove the air reference hose (3) from the fuel tank pressure sensor. Remove the fastener (4) securing the fuel tank pressure sensor to the fuel tank connection cover and remove the fuel tank pressure sensor.
- Remove the spring loaded clamp (1) around the fuel tank boot. See Fig 2. Note the position of the clamp. The clamp must be reinstalled in the same position. Carefully pull the boot from the outer fuel tank housing.
- Remove the fuel sender locking nut from the fuel tank by using the Fuel Tank Sender Wrench (J-42219-B) fuel tank sender wrench. See Fig 3. Lift the fuel tank connection cover from the tank and position aside. Remove the fuel level sensor electrical connector (1) from the fuel tank connection cover. See Fig 4.
- Unlock the fuel sensor by pressing the hook outward. Remove the fuel sensor by pulling upward on the hook to slide the unit from the fuel pump housing. Remove the fuel sender seal (lip) from the fuel tank opening. Carefully slide the seal over the wiring and hoses, then pull the seal over the fuel tank connection cover. Discard the seal.
- Install the fuel level sender in the tank by positioning the float in first and sliding the unit into the slots in the side of the fuel reservoir. Push the unit down in the slot until the tab on the hook engages in the reservoir. Connect the fuel level sender electrical connector to the fuel tank connection cover.
- Install a NEW lip seal on the tank as follows: Carefully pull the seal over the fuel tank connection cover. Slide the seal over the wires and hoses to the fuel tank opening. Fit the groove in the side of the seal into the lip in the fuel tank opening. Install the fuel tank connection cover on the fuel tank opening.
- To complete installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .
CAUTION:
DO NOT remove the steel band around fuel sender lock nut. This steel band does not require removal in order the loosen the fuel sender lock nut.
CAUTION:
Note the position of the fuel sender seal prior to removal. An incorrectly installed seal can cause fuel leaks or EVAP DTCs to set.