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 assembly.




2. Disconnect the fuel tank pressure sensor connector (1), the fuel pump connector (2), and the EVAP vapor hose quick connector (3), from the modular fuel pump and sender assembly cover (4).




3. Remove the flanged nut securing the modular fuel pump and sender assembly ground terminal to the fuel tank flange stud, and remove the fuel tank wiring harness.




4. Using the J 45722 (2) and a half-inch breaker bar (1), remove the cover retainer lock ring (3) by turning in a counterclockwise direction.




5. Partially lift the modular fuel pump and sender assembly away from the fuel tank, taking care not to damage the fuel level sender assembly.
6. Disconnect the fuel tank evaporative emission (EVAP) vapor line quick connector from the underside of the modular fuel pump and sender assembly cover.
7. Insert hand into the fuel tank opening and disconnect the fuel feed line quick connector.
8. Remove the modular fuel pump and sender assembly.
9. Remove and discard the modular fuel pump and sender assembly to fuel tank seal.

IMPORTANT:
- Fuel vapor remains in the tank even when completely empty. Seal the opening in the fuel tank using a suitable plug and place a suitable cover over the plug to prevent any foreign matter from entering
- Check the underside of the reservoir to ensure that there are 3 rubber isolator feet attached to the bottom. If one or more are missing, retrieve each from within the fuel tank and reinstall

INSTALLATION PROCEDURE
1. Before installation into the fuel tank, check the fuel sender float position.
- Stand the assembly upright on a flat surface.
- Measure the distance between the middle of the fuel sender float and the flat surface.
- If required, the float position should be corrected, through careful adjustment of the float arm.
7-14 mm.

IMPORTANT: Upon installation of the modular fuel pump and sender assembly, only use the custom sized O-rings as supplied with modular fuel pump and sender assembly replacement parts kit. Do not use off-the-shelf O-rings.

2. Clean any dirt and foreign materials from the fuel tank seal recess and position a new seal in the recess.
3. Install the modular fuel pump and sender assembly into the fuel tank, taking care not to damage the fuel level sender float and arm in the process.
4. Insert hand into the fuel tank opening and connect the fuel feed line quick connector.
5. Connect the fuel tank EVAP vapor line quick connector from the underside of the modular fuel pump and sender assembly cover.




6. Ensure the locator in the cover engages in the slot in the tank opening.




7. Install the cover retainer lock ring. Use the half-inch breaker bar with J 45722 and rotate the retainer in a clockwise direction until the tangs are engaged.




8. Install the fuel tank wiring harness, and the flanged nut securing the modular fuel pump and sender assembly ground terminal to the fuel tank flange stud.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the flange nut to 7 N.m (62 lb in).




9. Install the fuel tank pressure sensor connector (1), the fuel pump connector (2), and the EVAP vapor hose quick connector (3) to the modular fuel pump and sender assembly cover (4).
10. Install the fuel tank assembly.