Fuel Pump: Service and Repair

FUEL SENDER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 45722 Fuel Sender Lock Ring Wrench

REMOVAL PROCEDURE
1. Remove the fuel tank.




2. Disconnect the fuel sender module electrical connectors.




3. Disconnect the fuel pipes from the fuel sender.

NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.




4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.Turn the lock ring in a counterclockwise direction.

NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.




5. Remove the fuel sender lock ring (1) and the fuel sender (2) from the fuel tank.
6. Remove and discard the fuel sender seal (3).
7. Remove the fuel level sensor from the fuel sender module.




8. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.

IMPORTANT:
- Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.
- Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
- Check the lock ring for flatness.

9. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
10. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

INSTALLATION PROCEDURE
1. Install the fuel level sensor to the fuel sender module.
2. Clean the fuel sender sealing flange.




3. Install the NEW fuel sender seal (3) to the fuel tank seal groove.

IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication to the seal groove.

4. Install the fuel sender (2) and the fuel sender lock ring (1).




5. Use the J 45722 in order to install the fuel sender lock ring.Turn the lock ring in a clockwise direction.




6. Install the fuel pipes to the fuel sender.




7. Install the fuel sender sensor electrical connectors.
8. Install the fuel tank.