Transfer Fuel Pump Module to Replac. Fuel Tank Assembly
Transfer Fuel Pump Module to Replacement Fuel Tank AssemblyNOTICE:
Clean all fuel pipes, hose connections, and surrounding areas prior to disassembly to prevent fuel system contamination.
1. Disconnect fuel feed and return lines from filter/regulator assembly.
2. Disconnect fuel pump vapor line from fuel tank vent pipe.
NOTICE:
To prevent retainer damage, do not attempt to remove retainer with a 12 in. or shorter ratchet/breaker bar.
IMPORTANT:
Spray fuel pump module cam-locking tang with penetrating oil prior to attempting removal.
3. Use Fuel Tank Lock Ring Remover SA9156E and remove fuel pump module retaining ring. A 1/2 in. drive ratchet/breaker bar (approximately 18 in. long) will easily loosen and remove lock ring.
NOTICE:
Care must be taken not to bend or twist fuel pump filter or sending unit float arm during removal/installation of fuel pump module. A damaged fuel pump filter restricts fuel flow to pump, and a bent sending unit float arm will not provide accurate readings. Care must also be taken to ensure fuel pump module is not dropped. Dropping a fuel pump module can dislodge internal components and cause excessive noise and/or internal leakage.
4. To prevent bending of sending unit float arm during removal, lift pump module up slightly to disengage orientation tabs and rotate module 90° clockwise until fuel lines are facing the 1:00 o'clock position (12:00 is toward front of tank).
5. Carefully lift the fuel pump module (with sending unit) straight up from the fuel tank until the bottom of the pump module is very close to the fuel tank opening. Then, tilt the pump module about 45° toward the right side of the tank and simultaneously lift it up and out of the tank opening watching that the level sender float arm is not being bent.
IMPORTANT:
Always replace the fuel pump module to tank seal (0-ring) whenever the assembly is removed. The correct seal is green in color. Do not use the older black seal.
6. Discard the fuel pump module to tank seal.
NOTICE:
If float arm requires repositioning to meet appropriate clearance specification, ensure that any bending is performed at the 90° bend near level sender. The short section of float arm going into level sender must be supported so that bending does not take place at level sender.
7. Verify that the float arm on the fuel level sender has not been bent by standing the fuel pump module on a flat, horizontal surface and measuring the distance from this surface and the bottom of the float. A 5/32 in. diameter drill bit can be used as a gage. The gage must freely pass between the float and the horizontal surface with no more than 1/16 in. clearance.
8. Inspect replacement fuel tank and clean the fuel tank seal groove of any foreign debris before installing a new seal.
9. Carefully install the fuel pump module with sending unit in the fuel tank by orienting the float to face the right side of the tank, tilting the pump module approximately 45°, and loading the float arm and pump into the tank opening. Insert the pump module all the way down into the tank and then rotate 90° counterclockwise to align the module orientation tabs with slots in the tank opening. Correctly oriented, the lines from the pump module will be facing the 10 o'clock position (12 o'clock is front of tank).
IMPORTANT:
The fuel pump retaining ring cannot be properly installed if the pump flange locator tabs are not aligned with the slots in the tank.
10. Install retaining lock ring using service tool SA9156E.
NOTICE:
Replace the plastic fuel line retainers whenever the fuel supply lines are disconnected at the fuel filter/pressure regulator and fuel rail. Install the new retainer into the female portion of the connection. Care must be taken to assure that the locking tab is centered in the window of the female connection. Firmly press the male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
11. Connect fuel pump vapor line to fuel tank vent pipe.
12. Connect fuel feed and return lines to filter/pressure regulator and pull back to confirm positive engagement.
13. Position fuel feed, fuel return and EVAP canister purge line in fuel tank retaining clip and "snap" shut.
14. Install "loose" retainer clip around fuel feed, return, and purge line at upsets and "snap" closed.