| Removal and Installation Special Tool(s) | | Wrench, Fuel Tank Sender Unit (310-069) 23-055 | General Equipment Transmission jack Worldwide Diagnostic System (WDS) WARNING:This procedure involves fuel additive handling. Be prepared for fuel additive spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. WARNING:Eye, hand, ear protection and protective clothing are required to be worn during any general service or removal and installation procedures of fuel additive system components. Failure to follow this instruction may result in personal injury. WARNING:In case of fuel additive fluid contact with the skin or the eyes, flush immediately with water for a minimum of 15 minutes and seek prompt medical attention. Failure to follow this instruction may result in personal injury. WARNING:If fuel additive fluid is swallowed, call a physician immediately. Rinse mouth immediately with water, do not induce vomiting. Failure to follow these instructions may result in personal injury. WARNING:Always provide adequate ventilation when working on the fuel additive system or related components. Failure to follow these instructions may result in personal injury. WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction. | | -
Drain the fuel tank.
For additional information, refer to: Fuel Tank Draining (310-00A Fuel System - General Information, General Procedures).
| | | -
Raise and support the vehicle.
For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
| | | -
Detach the exhaust system from the middle hanger insulator. | | | -
Remove the exhaust flange nuts. - Discard the gasket and exhaust flange retaining nuts.
| | | -
NOTE:With the aid of another technician support the exhaust. Detach the exhaust system from the front hanger insulators. | | | -
Position the exhaust system to one side and secure it to the body with tie-straps. | 7. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Exhaust pipe center heat shield retaining bolts 8. To install, reverse the removal procedure. | | -
For vehicles with global closing initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
| Removal Details Item 3 : Fuel tank filler hose retaining clamps | | -
NOTE:Make a note of the position of the fuel tank filler hose retaining clamp. Make sure that the new replacement screw type clamp is positioned so that the screw head is in the same position as the original filler hose retaining clamp. Remove and discard the fuel tank filler hose retaining clamp. | | | -
NOTE:Make a note of the position of the fuel tank filler hose retaining clamp. Make sure that the new replacement screw type clamp is positioned so that the screw head is in the same position as the original filler hose retaining clamp. Remove and discard the fuel tank filler hose retaining clamp (rear sub-frame shown removed for clarity). | Item 4 : Fuel tank filler hose | | -
CAUTION:When removing the fuel tank filler hose, do not use any sharp edge tools to lever off the pipes. Failure to follow this instruction may result in damage to the filler hose. Remove the fuel tank filler hose. | Item 5 : Fuel tank vent hose retaining clamp | | -
NOTE:Make a note of the position of the fuel tank vent hose retaining clamp. Make sure that the new replacement screw type clamp is positioned so that the screw head is in the same position as the original vent hose retaining clamp. Remove and discard the fuel tank vent hose retaining clamp (rear sub-frame shown removed for clarity). | Item 6 : Fuel tank vent hose | | -
CAUTION:When removing the fuel tank vent hose, do not use any sharp edge tools to lever off the pipes. Failure to follow this instruction may result in damage to the vent hose. Disconnect the fuel tank vent hose from the fuel tank filler pipe. | Item 7 : Fuel tank additive tank vent pipe retaining clip | | -
Detach the fuel tank additive tank vent pipe retaining clip from the fuel tank vent hose. | Item 8 : Fuel tank fuel return line spring lock coupling | | -
Disconnect the fuel tank fuel return line spring lock coupling.
For additional information, refer to: Spring Lock Couplings (310-00A Fuel System - General Information, General Procedures).
| Item 9 : Fuel tank fuel supply line quick release coupling | | -
Disconnect the fuel tank fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
| Item 10 : Fuel additive tank to fuel tank line quick release coupling | | -
Disconnect the fuel additive tank to fuel tank line quick release coupling from the fuel tank. - Release the locking tangs
| Item 11 : Fuel tank support straps CAUTION:When supporting the fuel tank, use a suitable packing material to prevent damage to the underside of the fuel tank. | | -
Place a suitable transmission jack under the fuel tank. | Item 12 : Fuel Tank CAUTION:When lowering the fuel tank, do not place excessive strain on the fuel lines and wiring harness. | | -
Partially lower the fuel tank. | Item 13 : Fuel tank module electrical connector | | -
Disconnect the fuel tank module electrical connector. | Item 14 : Fuel tank vent hose retaining clamp | | -
NOTE:Make a note of the position of the fuel tank vent hose retaining clamp. Make sure that the new replacement screw type clamp is positioned so that the screw head is in the same position as as the original vent hose retaining clamp. Remove and discard the fuel tank vent hose retaining clamp. | Item 15 : Fuel tank vent hose | | -
CAUTION:When removing the fuel tank vent hose, do not use any sharp edge tools to lever off the pipes. Failure to follow this instruction may result in damage to the vent hose. Remove the fuel tank vent hose from the fuel tank. | Item 16 : Fuel tank fuel return line quick release coupling | | -
Disconnect the fuel tank fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
| Item 17 : Fuel tank fuel supply line quick release coupling | | -
Disconnect the fuel tank fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
| Item 18 : Fuel tank module locking ring | | -
Using the special tool, remove the fuel tank module locking ring. | Item 19 : Fuel tank module CAUTION:Make sure the fuel tank level sensor float and arm are not damaged during the removal of the fuel tank module. Installation Details Item 19 : Fuel tank module | | -
CAUTION:Make sure the fuel tank level sensor float and arm are not damaged during the installation of the fuel tank module. Make sure the arrows on the fuel tank and fuel tank module are aligned correctly. | Item 18 : Fuel tank module locking ring | | -
Using the special tool, install the fuel tank module locking ring. | Item 14 : Fuel tank vent hose retaining clamp | | -
Install a new fuel tank vent hose retaining clamp in the position shown. | Item 12 : Fuel Tank CAUTION:When installing the fuel tank, make sure the fuel lines do not get kinked or trapped. | | -
Partially raise the fuel tank. | Item 13 : Fuel tank module electrical connector | | -
Connect the fuel tank module electrical connector. | Item 11 : Fuel tank support straps | | -
Install the fuel tank support strap retaining bolts and remove the transmission jack. | Item 5 : Fuel tank vent hose retaining clamp | | -
Install a new fuel tank filler hose retaining clamp in the position shown (rear sub-frame shown removed for clarity). | Item 3 : Fuel tank filler hose retaining clamps | | -
Install a new fuel tank filler hose retaining clamp in the position shown. | | | -
Install a new fuel tank filler hose retaining clamp in the position shown (rear sub-frame shown removed for clarity). | |
