REMOVAL & INSTALLATION
Except 3.8L Engine
See Figures 1 through 7
Disconnect the negative battery cable. Place a suitable drain pan under the radiator.
Open the radiator drain cock and drain the cooling system a level below the thermostat. Close the drain cock and tighten to 13 inch lbs. (1.5 Nm).
Disconnect the air cleaner duct and remove the air cleaner.
Remove the inlet hose and clamp from the water outlet.
Fig. 1: Use a pair of pliers to unfasten the hose retaining clamp
Fig. 2: Disconnect the hose from the water outlet
Unfasten the water outlet bolts/screws, then remove the outlet.
Fig. 3: Unfasten the water outlet retaining bolts ...
Fig. 4: ... then remove the outlet to access the thermostat
If equipped, remove and discard the water outlet gasket. Remove the thermostat from the intake manifold or water pump.
Fig. 5: Remove the thermostat from the water pump
Thoroughly clean the gasket mating surfaces of the water outlet and upper intake manifold.
Fig. 6: Exploded view of the water outlet and thermostat - 3.4L engine
Fig. 7: Exploded view of the thermostat mounting - 5.7L engine
Place the thermostat into the intake manifold or water pump, as applicable. If equipped, place a new gasket over the thermostat.
Install the water outlet and secure with the retaining bolt/screw. Tighten to 21 ft. lbs. (28 Nm).
Install the inlet hose and clamp to the water outlet.
Install the air cleaner and air intake duct.
Fill and bleed the cooling system.
See Figures 1, 2, 3 and 4
The in-line fuel filter is located on the fuel feed pipe, before the fuel injection system, and mounted directly in front of the rear axle. The filter housing is constructed of steel with quick-connect inlet and threaded outlet fittings. The threaded fitting is sealed with an O-ring. In order to disengage quick-connect fittings, a fuel line quick-connect separator tool set, such as J-37088-A or equivalent, is required. There is no service interval for fuel filter replacement. Only replace the fuel filter if it is restricted.
Fig. 1: Cross-sectional view of the in-line fuel filter
Release the fuel pressure as follows:
In order to perform this procedure as listed below, fuel pressure gauge kit J-34730-1 or equivalent is required.
Disconnect the negative battery cable.
Loosen the fuel tank filler cap in order to relieve the fuel vapor pressure from the fuel tank.
Connect fuel pressure gauge J 34730-1 or equivalent to the fuel pressure connection. To avoid spillage while disconnecting gauge, wrap a shop towel around the fitting.
Install the bleed hose from the gauge into an approved container and open the valve to bleed the fuel system pressure.
At this point, fuel connections are now safe for servicing.
Raise and safely support the vehicle.
Clean both the inlet and the outlet fittings on the fuel filter.
Fig. 2: The in-line fuel filter is mounted in a bracket located under the vehicle, directly in front of the rear axle
Fig. 3: The fuel filter can be accessed with the vehicle raised and safely supported
Disengage the quick-connect fittings at the fuel filter inlet as follows:
Slide the dust covers from the quick-connect fittings, if equipped.
Grasp both sides of the fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within the fitting. Using compressed air and safety glasses, blow dirt out of fitting.
If equipped with the plastic hand releasable fitting, squeeze the plastic retainer release tabs and pull the connection apart.
If equipped with metal fitting, choose correct size tool from tool set J-37088-A. Insert tool into female connector, then push inward to release locking tabs. Pull the connector apart.
Use a clean lint free rag to clean male pipe ends. Inspect both ends of the fitting for dirt and burrs. Clean or replace components as required. If it is necessary to remove rust or burrs from the fuel pipe, use emery cloth in a radial motion with the pipe end to prevent damage to the O-ring sealing surface.
Fig. 4: Quick-connect fuel line fittings
Remove the threaded outlet fitting from the chassis fuel pipe. Slide the fuel filter from the bracket.
Inspect the fuel pipe O-ring for cuts, nicks, swelling or distortion. Replace if necessary.
Slide the fuel filter into the bracket. Thread the outlet fitting to the chassis fuel pipe.
Tighten the in-line fitting to 20 ft. lbs. (27 Nm).
Engage the quick-connect inlet fitting as follows:
Apply a few drops of clean engine oil to the male pipe end. This will ensure proper reconnection and prevent a possible fuel leak.
Push both sides of the fitting together to cause the retainer tabs to snap in place. Once installed, pull on both sides of the fitting to ensure connection is secure.
Reposition dust cover over the quick-connect fitting, if equipped.
Lower the vehicle. Tighten the fuel filler cap.
Confirm that the ignition is in the OFF position. Connect the negative battery cable.
Pressurize the fuel system by cycling the ignition without attempting to start the engine. Turn the ignition switch to the ON position for two seconds, then turn to the OFF position for ten seconds. Again, turn to the ON position and check for fuel leaks.
Here is other information.
Remove or Disconnect
Install or Connect