Fuel Tank Fuel Pump Module Replacement

Fuel Tank Fuel Pump Module Replacement

Special Tools

J 45722 - Fuel Sender Lock Nut Wrench

Removal Procedure





Warning:
Refer to Battery Disconnect Warning Service Precautions.


1. Disconnect the negative battery cable.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027)Fuel Pressure Relief (CH-48027) Fuel Pressure Relief (CH-48027).

3. Drain the fuel tank. Refer to Fuel Tank Draining (L59) ProceduresFuel Tank Draining (Without L59) Procedures.

4. Remove the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Rear Tank) Removal and ReplacementFuel Tank Replacement (Cutaway Van Side Tank) Removal and ReplacementFuel Tank Replacement (Passenger/Cargo) Removal and Replacement.





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

Caution:
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.

Note:
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. Use the J 45722 - Fuel Sender Lock Nut Wrench and a long breaker-bar in order to unlock the fuel sender lock ring.

6. Remove the fuel sender assembly and the seal. Discard the seal.

Warning

Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container

7. Clean the fuel sender sealing surfaces.





Note:

* 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.

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

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





Warning

In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Install the new seal on the fuel tank.

Note:
The fuel strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel strainer does not block full travel of the float arm.

2. Install the fuel sender assembly into the fuel tank.





Note:
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 in the seal groove.

Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

3. Use the J 45722 - Fuel Sender Lock Nut Wrench in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.

4. Install the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Rear Tank) Removal and ReplacementFuel Tank Replacement (Cutaway Van Side Tank) Removal and ReplacementFuel Tank Replacement (Passenger/Cargo) Removal and Replacement.

5. Refill the fuel tank.

6. Tighten the fuel filler cap.

7. Connect the negative battery cable.

8. Inspect for leaks:

1. Turn ON the ignition for 2 seconds.

2. Turn OFF the ignition for 10 seconds.

3. Turn ON the ignition.

4. Inspect for fuel leaks.