Fuel Filter: Service and Repair

FUEL PUMP AND FUEL FILTER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
CH-47717 Fuel Lock Ring Remover Tool

REMOVAL PROCEDURE
The fuel pump and the fuel filter are an integral part of the fuel sender assembly and cannot be serviced separately. Replacement of the fuel sender assembly is required in order to replace the fuel pump or the fuel filter.

IMPORTANT:
- Always replace the fuel sender assembly O-rings when reinstalling the fuel sender assembly.
- Always maintain cleanliness when servicing fuel system components.
- Do not bend the arm of the fuel gage float while removing the fuel sender assembly.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.




2. Remove the 2 fasteners (2) of the right side cushion (1) and swing the rear seat bottom cushion (1) up and out of the way.
3. Remove the sill plate from the right side door opening.
4. Fold back the carpet, in order to maintain metal-to-metal contact, while servicing the fuel sender assembly.




5. Remove the 4 fasteners to the access panel (1) for the fuel sender assembly from the rear seat floor (3).
6. Lift the access panel (1) and disconnect the fuel sender electrical connector (2) from the fuel sender assembly.




7. Remove the retaining clip (1) from the fuel line fitting (2).




8. Disconnect the fuel line (1) from the fuel sender assembly.




9. Unlock the quick connect fitting of the on-board refueling vapor recovery (ORVR) vent line by sliding the lock clasp (1) to unlock position.




10. Disconnect the ORVR vent line (2) from the fuel sender assembly (1).




11. Use the CH-47717 (1) in order to loosen the fuel sender assembly lock ring.
12. Clean the area around the fuel and vent lines and the fuel sender assembly in order to prevent possible fuel contamination during removal.




13. Locate the 4 safety latches (1, 3) and the safety stop (2) on the fuel sender assembly lock ring.
14. While rotating the lock ring during removal, ensure that each safety latch is gently depressed in order to pass without engaging the safety stop.




15. Remove the lock ring (1).

16. IMPORTANT: Do not spill residual fuel or damage the fuel level sensor float while rotating and tilting the sender assembly during removal.

Remove the fuel sender assembly (2) from the fuel tank.

INSTALLATION PROCEDURE

NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.




1. Install a new O-ring seal (1) onto the fuel tank.




2. Install the fuel sender assembly (2) into the fuel tank through the floor panel opening (3).




3. Align the notch (1) on the fuel sender assembly with the slot (2) in the fuel tank opening.




4. Align the extra ridge (1) on the fuel tank lock ring with the mark (2) on the fuel tank.
5. Gently push down on the fuel sender while rotating the lock ring onto the fuel tank.




6. Use the CH-47717 (1) in order to tighten the fuel sender assembly lock ring.




7. After 2 full rotations of the lock ring, watch for the alignment of the lock ring extra ridge (1) with the 2 triangle marks (2) on the fuel tank.
8. Rotate the lock ring until the ridge (1) is positioned within the 16° area (3) between the 2 marks (2).




9. Connect the ORVR vent line (2) to the fuel sender assembly (1).




10. Slide the quick connect clasp (1) into the lock position on the ORVR vent line (2).




11. Connect the fuel supply line (1) to the fuel sender assembly.




12. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).




13. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
14. Add fuel to the fuel tank.

15. NOTE: Refer to Fastener Notice.

Connect the negative battery cable.

Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).
16. Pressurize the fuel system and check for leaks.
17. Install the access panel (1) to the rear seat floor panel (3).
18. Secure the access panel to the body with 4 bolts.

Tighten the 4 bolts to 6 N.m (53 lb in).
19. Relocate the carpet under the ride side seat area and the right sill plate area.
20. Install the sill plate to the right side door opening.




21. Lower the rear seat bottom cushion (1) and secure with 2 bolts (2).

Tighten the 2 bolts to 41 N.m (30 lb ft).