Service Procedure
1. With the ignition key in the OFF position, disconnect the battery.Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
2. Remove the fuel filler cap.
3. Insert a syphon hose into the fuel filler tube, and drain the fuel into an approved gasoline holding tank.
4. Release the fuel system pressure as follows:
a. Remove the protective cap from the fuel pressure test port on the fuel rail (Figure 1).
b. Place the open end of fuel pressure release hose (C-4799-1) into an approved gasoline container. Connect the other end of the hose to the fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.
c. Remove the pressure release hose and install the protective cap.
5. Remove the three (3) screws which secure the filler tube to the body.
6. Raise the vehicle on an appropriate hoist until the wheel well is at working level (shoulder height).
7. Remove the four (4) push clips which secure the left rear fender well splash shield to the body and then remove the splash shield (Figure 2).
8. Raise the vehicle fully.
9. Remove the three (3) filler tube blocker bracket attaching screws and remove the blocker bracket (Figure 3).
10. Disconnect the two (2) filler vent hoses from the filler tube assembly by gently squeezing the retainer and pulling the connector off of the steel tube on the filler tube (Figure 4).
CAUTION:
Make sure the vent hose connector O-ring and retainer remain in position inside the connector. Spare O-rings and retainers are provided if necessary.
11. Loosen the filler tube to tank inlet neck hose clamp at the tank connection (Figure 4).
12. Carefully remove the filler tube hose from the fuel tank inlet neck, then remove the filler tube from the vehicle and discard it.
13. Disconnect the rollover valve harness to steel vent tube connection at the front of the fuel tank (Figure 5).
14. Disconnect the fuel filter supply hose from the steel supply tube (Figure 6).
CAUTION:
Hold a shop towel to the connection. Although the fuel pressure was released~ fuel remaining in the tube will drain out after the line is disconnected.
15. Slide the fuel pump module electrical connector lock to the unlocked position (Figure 7). Then push down on the connector retainer and pull the connector from the module (Figure 8).
16. Use a transmission jack to support the fuel tank.
17. Remove the four (4) fuel tank support strap bolts and remove the straps.
18. Lower the fuel tank slowly while feeding the vent hoses through the frame rail opening and remove the fuel tank from the vehicle.
19. Cap the tank filler nipple and clean the top of the fuel tank if necessary.
20. Using a knife or razor, cut the front rollover valve hose one inch (25 mm) from the tee as shown (Figure 9).
21. Cut the rear tank rollover valve harness one inch (25 mm) from the in-line connector as shown (Figure 10). Discard the old harness.
22. Attach the elbow connector of the provided dual rollover valve- to-filler hose harness assembly to the front tank rollover valve hose. Use lubricant to ease installation, if necessary. Then tape the hose to the tank at the front strap area (Figure 11).
23. Attach the straight connector of the dual rollover valve-to-filler hose harness assembly to the rear tank rollover valve hose. Use lubricant to ease installation, if necessary. Then tape the line to the fuel tank at the rear strap area (Figure 11).
24. Using three of the provided small tie straps, fasten the two hoses of the dual rollover valve-to-filler hose harness assembly together as shown in Figure 11.
NOTE:
Locate the tie strap that is closest to the tank as close to the rubber inline connector as possible.
25. Attach the provided single canister-to-filler hose onto the steel vent tube near the left frame rail. Route the vent hose along the rail and feed it through the frame rail opening. Secure the vent hose to the inboard side of the brake tubes with the remaining small tie strap (Figure 12).
26. Place the fuel tank on a transmission jack and slowly raise the tank into position while feeding the rollover valve harness and fuel filler vent hoses through the frame rail opening. Make sure the vent hoses are not crossed on top of the tank and be careful not to kink the rollover valve hoses (Figure 13).
27. Install the fuel tank support straps. Tighten the bolts to 40 ft-lbs (54 Nm).
28. Insert the provided fuel filler tube through the wheel well and attach the filler tube to the fuel tank inlet neck. DO NOT TIGHTEN THE FILLER TUBE HOSE CLAMP. Make sure all hoses coming through the frame rail opening are to the rear of the filler tube.
29. Lubricate the two filler tube vent hose connectors and attach the vent hoses to the filler tube by pushing the connectors on until they are seated and a 'click' is heard. Pull back on the connectors to make sure the connections are secure.
NOTE:
Make sure both vent hose connections have the O-ring and retainer in the proper position. Extra O-rings and retainers have been provided if necessary.
30. Push the fuel filter supply hose connector on to the steel fuel supply tube until it is seated. Pull back on the connector to make sure it is secure (Figure 6).
31. Attach the fuel pump module electrical connector. Be sure to slide the retainer into the locked position (Figure 7).
32. Lower the vehicle until the filler tube and wheel well are at a working level (shoulder height).
33. Attach the filler tube to the body. Tighten the screws to 20 in-lbs (2.5 Nm).
34. Route the dual rollover valve hose harness below the vent tube and then attach the Y-Connector to the lower nipple on the filler tube (Figure 14).
35. Attach the single vent hose to the filler tube rollover valve (upper) nipple. Make sure the hoses are not kinked (Figure 14).
36. Secure the vent hoses to the filler tube with the medium tie strap as shown in Figure 15.
37. Raise the vehicle fully.
38. Tighten the fuel filler tube hose clamp at the fuel tank connection to 30 in-lbs (3.5 Nm).
39. Using a vice, bend the rear edge of the filler tube blocker bracket at least 450 as shown in Figure 16.
40. Install the filler tube blocker bracket. Tighten the bolts to 50 in-lbs (5.5 Nm).
41. Clip the free end of the filler tube ground strap onto the rear edge of the filler tube blocker bracket (Figure 17).
42. Reinstall the rear fender splash shield using the provided push clips.
43. Lower the vehicle and refill the fuel tank.
44. Connect the negative battery cable.
45. Start the engine and check all of the connections to insure that there are no fuel leaks.
46. Using a ball point pen, print your dealer code (5 digits) on the supplied Recall Completion Label.
47. Peel the recall completion label from its backing and apply it near the Vehicle Emission Control Information (VECI) label on the right shock tower.