Installation Procedure
Fuel Hose (4) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Sender (3) - Connect [2x] - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Vent Hose (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Electrical Connector (1) - Connect
Fuel Pump Seal (2) - Install NEW
- Fuel Tank Fuel Pump Module (1) - Install
Fuel Sender Retainer (1) - Install - CH - 45722 Fuel Sender Lock Ring Wrench (2)
Evaporative Emission Canister Hose (4) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Filler Evaporative Emission Valve Hose (3) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Pump Fuel Feed Hose (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Sender Wiring Harness (1) - Connect [3x]
Place a suitable adjustable jack under the fuel tank.
- Fuel Tank (1) - Install
Fuel Tank Strap (2) - Install [2x]
- Fuel Tank Strap Bolt (1) - Install and tighten [5x] - Fastener Specifications
- Remove the jack.
Fuel Tank Vent Hose (5) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Filler Evaporative Emission Valve Hose (4) - Connect - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Hose (3) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Filler Hose (2) - Install
- Fuel Tank Filler Hose Clamp (1) - Tighten - Fastener Specifications
Fuel Pump Fuel Feed Hose (2) - Connect - Plastic Collar Quick Connect Fitting Service
- Fuel Tank Vent Valve Hose (1) - Connect - Plastic Collar Quick Connect Fitting Service
Retainer (2) - Engage [5x]
- Fuel Sender Wiring Harness (1) - Connect [2x]
Transmission Fluid Auxiliary Cooler Outlet Pipe (2) - Install
- Transmission Fluid Auxiliary Cooler Outlet Pipe (2) - Connect
- Retaining Clip (3) - Engage
- Transmission Fluid Cooler Pipe Clip (1) - Engage [2x]
Transmission Fluid Auxiliary Cooler Inlet Pipe (2) - Install
- Transmission Fluid Auxiliary Cooler Inlet Pipe (2) - Connect
- Retaining Clip (3) - Engage
- Transmission Fluid Cooler Pipe Clip (1) - Engage [2x]
Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Fluid Auxiliary Cooler Outlet Pipe (4) - Connect
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Fluid Auxiliary Cooler Inlet Pipe (1) - Connect
- Retaining Clip (3) - Engage [2x]
Position the propeller shaft (1) in the vehicle.
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation.
- Install the 2 propeller shaft bearing support bolts (1) and tighten. Fastener Specifications
Align the reference mark (3) between the propeller shaft flange (1) and the rear axle pinion flange (2).
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation.
- Install the 3 rear propeller shaft nuts (2) and the 3 rear propeller shaft bolts (1).
- Tighten the 3 rear propeller shaft bolts (1). Fastener Specifications
Align the reference mark (2) between the propeller shaft flange (3) and the output flange (1) of the transmission.
If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Apply liquid thread locking adhesive in a strip along half of the length of the external threads, starting at the tip, just prior to installation.
- Install the 3 front propeller shaft nuts (1) and the 3 front propeller shaft bolts (2).
- Tighten the 3 front propeller shaft bolts (2). Fastener Specifications
Transmission Mount (2) - Install
- Transmission Mount Bolt (1) - Loosely install [2x]
Transmission Mount Bracket Bolt (1) - Loosely install [4x]
Transmission Mount Bolt (1) - Tighten [2x] - Fastener Specifications
Transmission Mount Bracket Bolt (1) - Tighten [4x] - Fastener Specifications
- Remove the jack stand.
Floor Panel Number 2 Cross Bar Reinforcement (2) - Install
- Floor Panel Number 2 Cross Bar Reinforcement Bolt (1) - Install and tighten [4x] - Fastener Specifications
Exhaust Intermediate Underbody Heat Shield (2) - Install
- Exhaust Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Catalytic Converter Gasket (2) - Install NEW
- With the aid of an assistant, install the exhaust muffler (1).
Exhaust Muffler Hanger Bracket Nut (1) - Install and tighten [4x] - Fastener Specifications
Electrical Connector (1) - Connect
Electrical Connector (1) - Connect
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Install [2x]
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Install [2x]
Exhaust Pipe Clamp (1) - Tighten [2x] - Fastener Specifications
Catalytic Converter Nut (1) - Install and tighten [2x] - Fastener Specifications
Floor Panel Reinforcement (2) - Install
- Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Install and tighten [6x] - Fastener Specifications
Underbody Rear Air Deflector- Left Side (5) - Install
- Transmission Fluid Cooler Pipe Bracket Bolt- Left Side (3) - Install and tighten [2x] - Fastener Specifications
- Underbody Rear Air Deflector Nut- Left Side (2) - Install and tighten [5x] - Fastener Specifications
- Underbody Front Air Deflector Bolt- Left Side (1) - Install and tighten [6x] - Fastener Specifications
Underbody Rear Air Deflector- Right Side (5) - Install
- Transmission Fluid Cooler Pipe Bracket Bolt- Right Side (3) - Install and tighten [2x] - Fastener Specifications
- Underbody Rear Air Deflector Nut- Right Side (2) - Install and tighten [5x] - Fastener Specifications
- Underbody Front Air Deflector Bolt- Right Side (1) - Install and tighten [6x] - Fastener Specifications
Underbody Rear Air Deflector- Right Side (5) - Install
- Underbody Rear Air Deflector Nut- Right Side (3) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Bolt- Right Side (2) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Nut- Right Side (4) - Install and tighten [2x] - Fastener Specifications
- Rear Wheelhouse Liner Bolt- Right Side (1) - Install and tighten - Fastener Specifications
Underbody Rear Air Deflector- Left Side (5) - Install
- Underbody Rear Air Deflector Nut- Left Side (2) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Bolt- Left Side (3) - Install and tighten [3x] - Fastener Specifications
- Underbody Rear Air Deflector Nut- Left Side (4) - Install and tighten [2x] - Fastener Specifications
- Rear Wheelhouse Liner Bolt- Left Side (1) - Install and tighten - Fastener Specifications
Rear Tire Front Air Deflector- Left Side and Right Side (2) - Install [2x]
- Rear Tire Front Air Deflector Bolt- Left Side and Right Side (1) - Install and tighten [4x] - Fastener Specifications
- Lower the vehicle.
- Refill the fuel tank.
- Check the transmission fluid level. Transmission Fluid Level and Condition Check
- Inspect for transmission fluid leaks. Fluid Leak Diagnosis
- Pressurize the fuel system and inspect for leaks.
- Inspect the exhaust system for leaks.
Refer to Fastener Caution .
For proper bolt alignment, loosely install all mount bolts prior to tightening to specifications.