Fuel Tank Module Replacement

FUEL TANK MODULE REPLACEMENT

TOOLS REQUIRED
- J 39765 Fuel Sender Lock Nut Wrench
- J39765-A Fuel Sender Lock Ring Tool

REMOVAL PROCEDURE
1. Remove the fuel tank.




2. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in order to disconnect the following from the fuel tank module (2):
- The evaporative emission (EVAP) pipe (5)
- The fuel return pipe (6)
- The fuel feed pipe (7)

NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
- The fuel pipe connections
- The hose connections
- The areas surrounding the connections




3. Rotate the cam lock ring (1) counter-clockwise using the J 39765 or J39765-A (2).

IMPORTANT: Do not allow the tool (2) to come in contact with the male pipe ends while unlocking the cam lock ring (1).

4. Remove the cam lock ring (1) from the fuel tank.




5. Complete the following in order to remove the fuel tank module (2) from the fuel tank (4):
1. Raise the module (2) upward from the fuel tank (4).
2. Tilt the module (2), to allow the fuel level sensor arm and float (3) to clear the fuel tank module opening.
6. Remove the fuel tank module seal (1).Do not reuse the seal (1).

CAUTION: 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 module sealing surfaces.

INSTALLATION PROCEDURE
1. Clean any contamination from the male pipe ends of the fuel tank module.




2. Place the new fuel tank module seal (1) on the fuel tank.

CAUTION: 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.

3. Complete the following in order to install the fuel tank module (2) into the fuel tank (4):
1. Insert the module (2) into the fuel tank allowing the fuel level sensor arm and float (3) to clear module opening.
2. Lower the module (2) downward into the fuel tank (4).




4. Press the fuel tank module downward, aligning the tang (1) with the notch (2) in the fuel tank.
5. Position the cam lock ring to the fuel tank




6. Rotate the cam lock ring (1) clockwise using the J 39765 or J39765-A (2) until fully seated.

IMPORTANT: Do not allow the tool (2) to come in contact with the male pipe ends while locking the cam lock ring (1).




7. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in order to connect the following to the fuel tank module (2):
- The evaporative emission (EVAP) pipe (5)
- The fuel return pipe (6)
- The fuel feed pipe (7)
8. Install the fuel tank.