| Removal and Installation Special Tool(s) | | Wrench, Sender Unit, Fuel Tank 310-069 (23-055) | General Equipment Materials Name Specification Petroleum Jelly WSM-M1C226-A Removal All vehicles 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. | | -
Release the fuel system pressure.
For additional information, refer to: Fuel System Pressure Release (310-00 Fuel System - General Information, General Procedures).
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Drain the fuel tank.
For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
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Raise and support the vehicle.
For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
| Wagon | | -
Detach the exhaust system from the front exhaust hanger insulator. | | | -
Detach the exhaust system from the middle exhaust hanger insulator. | All vehicles | | -
Detach the exhaust system from the rear exhaust hanger insulator. | | | -
Remove the exhaust system heat shield. | All except vehicles with diesel engine | | -
Disconnect the fuel tank to fuel filter fuel supply line and the fuel filter to fuel injection supply manifold fuel supply line from the fuel filter.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| Vehicles with 115 PS diesel engine All vehicles | | -
Disconnect the fuel tank filler pipe from the fuel tank. | | | -
CAUTION:When removing the fuel tank vent pipe, do not use any sharp edged tools to lever off the pipe. Failure to follow this instruction may cause damage to the vent pipe. Disconnect the fuel tank vent pipe from the fuel tank. | Vehicles with xenon headlamps | | -
Remove the headlamp leveling sensor.
For additional information, refer to: Headlamp Leveling Sensor - Vehicles With: High Intensity Discharge Headlamps (417-01 Exterior Lighting, Removal and Installation).
| All Vehicles | | -
Detach the stabilizer bar connecting link from the stabilizer bar on both sides. | | | -
Remove the stabilizer bar bush retaining clamps from both sides and remove the stabilizer bar. | | | -
CAUTION:Use a suitable packing material to prevent damage to the underside of the fuel tank and heat shield. | | | -
Detach the fuel tank support straps. | | | -
Remove the fuel tank support straps. - Rotate the fuel tank support straps.
- Pull the fuel tank support straps down to remove.
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Disconnect the fuel return line.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
| All except vehicles with diesel engine | | -
Disconnect the evaporative emission canister purge valve hose from the fuel tank. | All vehicles | | -
CAUTION:When lowering the fuel tank, make sure that excessive strain is not placed on the fuel lines and electrical connectors. Partially lower the fuel tank. | All except vehicles with diesel engine | | -
Disconnect the fuel pump module electrical connector. | | | -
Disconnect the fuel supply and fuel return lines from the fuel pump module. | Vehicles with diesel engine | | -
Disconnect the fuel level sensor electrical connector. | | | -
Disconnect the fuel supply and fuel return lines from the fuel level sensor. | All vehicles All except vehicles with diesel engine | | -
Using the special tool, remove the fuel pump module locking ring. | | | -
CAUTION:Make sure that the float or arm are not damaged while removing or installing the fuel pump module. Remove the fuel pump module. - Rotate the module counterclockwise.
- Lift the module from the fuel tank.
| Vehicles with diesel engine | | -
Using the special tool, remove the fuel level sensor locking ring. | | | -
CAUTION:Make sure that the float or arm are not damaged while removing or installing the fuel level sensor. Remove the fuel level sensor. - Rotate the sensor counterclockwise.
- Lift the sensor from the fuel tank.
| Installation 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:Lubricate the fuel tank filler pipe lower end to aid installation and to make sure that the fuel tank filler pipe seal in the fuel tank is not damaged during installation of the fuel tank filler pipe. NOTE:Inspect the fuel tank filler pipe seal inside the fuel tank for damage. Install a new fuel tank if the seal is damaged. NOTE:Install a new O-ring seal and make sure it is seated correctly on the fuel tank. NOTE:Make sure that the arrows on the fuel tank and fuel pump module or fuel level sensor are aligned correctly. NOTE:Make sure that the insulator pads are fitted to the fuel tank support straps. | | -
To install, reverse the removal procedure. - Using suitable petroleum jelly lubricate the fuel tank filler pipe before inserting it into the fuel tank.
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