Transfer Fuel Pump - G6-, REMOVING AND INSTALLING, VEHICLES WITH 3.0L (V6)/4.2L (V8) ENGINES THROUGH 05/2010: Installing

Install in reverse order of removal. Note the following:

• Tightening specifications, refer to OVERVIEW - FUEL DELIVERY UNIT/SUCTION JETION PUMP/FUEL LEVEL SENSOR, VEHICLES WITH 3.0L (V6)/4.2L (V8) ENGINES THROUGH 05/2010 .

-- Install the fuel delivery unit into the fuel tank.

Fig 1: Fuel Delivery Components Location

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• The notch -2- on the fuel delivery unit then aligns with the tab -1- on the retaining ring.
• It must be possible to push the fuel delivery unit downward.

-- Turn the fuel delivery unit -3- 15°-clockwise -arrow- to secure it (bayonet connection).

-- Push the fuel lines through the right opening in the fuel tank into the left fuel tank chamber.

Fig 2: Fuel Lines Location

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-- Push the suction jet line -3- onto the suction jet pump until it clicks into place.

-- Push the supply line -4- on until it clicks into place on the fuel delivery unit.

-- Push the fuel lines -1 and 2- onto the right locking flange until they click into place.

-- Disconnect the connector -1- from the fuel pump on the bottom side of the right locking flange.

Fig 3: Identifying Electrical Connectors -1 - And -2- On Underside Of Right Locking Flange

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-- Wrap the wire -2- for the Fuel Level Sensor -G- twice around the wire -1- for the fuel pump and then connect it to the right locking flange.

-- Install the new seal for the right locking flange dry.

-- Bring the right locking flange into the installation position. Refer to Installing .

Fig 4: Aligning Tab -2- On Right Locking Flange Between Tabs -1- And -3-

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• Tab -2- on right locking flange faces toward arrow marking and must lie between tabs -1 and 3- on fuel tank.

-- Reach into the left opening in the fuel tank and connect the fuel lines -3 and 4- until they click into place.

Fig 5: Connecting Fuel Lines

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-- Connect the connectors -1 and 2- on the bottom of the left locking flange.

Fig 6: Locking Flange Connectors

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-- Install the new seal for the left locking flange dry.

-- Bring the left locking flange into the installation position:

Fig 7: Aligning Tab -2- On Left Locking Flange Between Tabs -1- And -3-

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• The tab -2- on left locking flange faces toward the arrow marking and must lie between tabs -1 and 2- on fuel tank.

-- Install the locking flange covers, refer to Figure.

-- Insert the frame into the floor covering, refer to the Parts Catalog and Interior Trim .

-- Install the right rear single seat in the second row of seats, refer to Seat Frames .

-- Install the left single seat and the left 2/3 seat bench seat cushion in the second row of seats, refer to Seat Frames .

-- Vehicles with parking heater: Bleed the fuel supply line to the metering pump, refer to FUEL SUPPLY LINE TO METERING PUMP, BLEEDING, VEHICLES WITH PARKING HEATER .

-- After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.