Fuel Tank Fuel Pump Module Replacement - Right Side

Fuel Tank Fuel Pump Module Replacement - Right Side

Tools Required

J39765-A Fuel Sender Lock Ring Tool

Removal Procedure




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
2. Remove the right fuel tank. Refer to Fuel Tank Replacement - Right Side (Service and Repair).
3. Place the fuel tank on a suitable work surface.




4. Disconnect the evaporative emissions (EVAP) purge line (4) from the fuel tank module.
5. Disconnect the fuel tank module harness connector (5).
6. Disconnect the fuel tank pressure (FTP) sensor harness connector (1).
7. If replacing the fuel tank module, remove the FTP sensor (2). Refer to Fuel Tank Pressure Sensor Replacement (Service and Repair).





Important: The fuel tank module is spring loaded and will spring upward when the locking ring is removed.


8. Using the J39765-A (1), remove the fuel tank module locking ring (2), by rotating the J39765-A in a counterclockwise direction.




9. Carefully remove the fuel tank module (2) from the fuel tank half way with the jet lines connected. Ensure not to damage the fuel level float arm.
10. Disconnect the internal fuel line quick-connect fittings from the fuel tank module ports, noting the location of the lines for installation.
11. Remove the fuel tank module from the fuel tank using care not to damage the fuel level float arm.
12. Remove the fuel tank module O-ring (3) from the fuel tank opening.

Installation Procedure




1. Install a NEW fuel tank module O-ring (3) to the fuel tank opening.

Important: Pull on each internal fuel line to ensure that the quick-connect fittings are secure.


2. Pull the internal fuel lines up through the fuel tank module opening and connect the internal fuel line quick-connect fittings to the fuel tank module ports in the location noted during disassembly.
3. Install the fuel tank module lock ring (1) into position on the fuel tank module.
4. Install the fuel tank module into the fuel tank, using care not to damage the fuel level sensor arm.
5. Compress and align the fuel tank module.




6. Using the J39765-A (1), fully lock the fuel tank module lock ring (2) in place, by rotating the J39765-A in a clockwise direction.
7. Using a digital multi-meter, verify the full and empty readings resistance reading of the fuel tank module. Turn the fuel tank upside down to achieve the full tank reading.

* Empty 250 resistance
* Full 40ohm resistance




8. Install the FTP sensor (2), if previously removed. Refer to Fuel Tank Pressure Sensor Replacement (Service and Repair).
9. Connect the FTP sensor harness connector (1).
10. Connect the fuel tank module harness connector (5).
11. Connect the EVAP purge line (4) to the fuel tank module.




12. Install the right fuel tank. Refer to Fuel Tank Replacement - Right Side (Service and Repair).
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
14. Perform the following procedure in order to test for leaks:

1. Turn ON the ignition switch, for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.

* Fuel pump on: 400 kPa (58 psi)
* Fuel pump off: 359 kPa (52 psi)

15. Program the transmitters. Refer to Transmitter Programming (N. America and Japan, except Canada) (Programming and Relearning)Transmitter Programming (Canada and Europe) (Programming and Relearning)Transmitter Programming (New RCDLRs ONLY) (Programming and Relearning).