Fuel Tank Unit: Service and Repair

Removal Of Fuel Pump/sender Module.:

Fuel Module Location.:

PRECAUTIONS


WARNING: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place. Anytime the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.

WARNING: Anytime the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.

CAUTION: Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam lock ring tangs with penetrating oil prior to attempting removal.

NOTE: For removal of the fuel sender from the Module assembly, refer to FUEL TANK SENDER REPLACEMENT PROCEDURES.



REMOVAL


1. Remove fuel tank. Refer to FUEL TANK REPLACEMENT PROCEDURE.


2. Use the lock ring service tool SA9156E (or equivalent) and remove the fuel pump module cam lock ring. A 1/2 in. breaker bar (approximately 18 inches long) will easily loosen and remove the lock ring. To prevent lock ring damage, do not attempt to remove the ring with a 12 in. or shorter ratchet/breaker bar.
NOTE: Care must be taken not to bend or twist the fuel pump filter or sending unit during removal or installation of fuel pump module assembly. A damaged fuel pump filter restricts fuel flow to the pump and a bent sending unit arm will not provide accurate readings.

3. Carefully lift the fuel pump module with sending unit assembly from the fuel tank at a 45 degree angle to prevent, filter sending unit and float arm damage.
WARNING: Always replace the fuel pump module to tank O-ring whenever the assembly is removed.

4. Discard the large fuel pump module to tank O-ring.
NOTE: Inspect the fuel tank for metal chips/debris. Remove all contaminants and replace the in-line fuel filter before installing a new fuel pump assembly when debris are present.

INSTALLATION

1. Inspect fuel tank and clean the fuel tank O-ring groove in of any foreign debris and install a new O-ring.

2. Carefully install the fuel pump module with sending unit assembly in the fuel tank at a 45 degree angle to prevent sending unit and float damage. The fuel filter and sending unit float arm must be directed toward the front of the tank. The fuel pump locator tabs must be aligned with the slots in the tank.
NOTE: The fuel pump lock ring can not be properly installed if the pump flange locator tabs are not aligned with the slots in the tank.

3. Install the cam-lock ring using lock ring service tool SA9156E, or equivalent.

4. Install the fuel tank. Refer to FUEL TANK REPLACEMENT PROCEDURE.