Primary Fuel Tank Module Replacement
Primary Fuel Tank Module Replacement
Special Tools
J 45722 Fuel Tank Sender Wrench.
Removal Procedure
1. Ignition OFF.
Warning:
Refer to Battery Disconnect Warning Battery Disconnect Warning.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.
Warning:
Refer to Gasoline/Gasoline Vapors Warning Service Precautions.
Warning:
Refer to Relieving Fuel Pressure Warning Service Precautions.
3. Relieve the low side fuel pressure. Refer to Fuel Pressure Relief (High Pressure) Fuel Pressure Relief (High Pressure)Fuel Pressure Relief (Low Pressure) Fuel Pressure Relief (Low Pressure).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
5. Remove the fuel tank assembly. Refer to Fuel Tank Replacement Removal and Replacement.
Note:
Press the locking tang (4) to release the electrical harness connector (1) from the primary fuel tank module (2).
6. Disconnect the electrical harness connector (1) from the primary fuel tank module (2).
7. Detach the fuel feed pipe (3) from the primary fuel tank module (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures.
Note:
The cam lock ring (2) is a single use item and must be discarded after removal.
8. Remove the cam lock ring (2) from the fuel tank assembly (3) by rotating the cam lock ring (2) counter-clockwise using the fuel tank sender wrench J 45722 (1).
9. Discard the cam lock ring (2)
Note:
To release the transfer tube connector (4) from the primary fuel tank module (1), squeeze the releasing buttons on the transfer tube connector (4).
Note:
Note the orientation of the primary fuel tank module (1) in relation to the fuel tank assembly (2).
10. Carefully lift the primary fuel tank module (1) from the fuel tank assembly (2), allowing enough clearance to disconnect the transfer tube connector (4) from the primary fuel tank module (1).
11. Disconnect the transfer tube connector (4) from the primary fuel tank module (1).
Note:
Care should be taken not to damage the fuel level sensor float rod (3) when removing the primary fuel tank module (1) from the fuel tank assembly (2).
12. Carefully manoeuvre the primary fuel tank module (1) from the fuel tank assembly (2)
Note:
The primary fuel tank module seal ring (1) is a single use item and must be discarded after removal.
13. Remove the primary fuel tank module seal ring (1) from the fuel tank assembly (2).
14. Discard the primary fuel tank module seal ring (1).
Installation Procedure
1. Install a NEW primary fuel tank module seal ring (1) to the fuel tank assembly (2).
Note:
Care should be taken not to damage the fuel level sensor float rod (3) when installing the primary fuel tank module (1) to the fuel tank assembly (2).
2. Carefully lower the primary fuel tank module (1) into the fuel tank assembly (2), enough to connect the transfer tube connector (4) to the primary fuel tank module (1).
Note:
Listen for an audible click to confirm the correct installation of the transfer tube connector (4) to the primary fuel tank module (1).
3. Connect the transfer tube connector (4) to the primary fuel tank module (1).
4. Install the primary fuel tank module (1) to the fuel tank assembly (2).
Note:
Apply suitable pressure onto the primary fuel tank module (4) to hold the primary fuel tank module (4) in place while installing the NEW cam lock ring (2)
5. Hold the primary fuel tank module (4) in place while installing the NEW cam lock ring (2) to the fuel tank assembly (3) by rotating the cam lock ring (2) clockwise using the fuel tank sender wrench J 45722 (1).
Note:
Listen for an audible click to confirm the correct installation of the electrical harness connector (1) to the primary fuel tank module (2).
6. Connect the electrical harness connector (1) to the primary fuel tank module (2).
7. Connect the fuel feed pipe (3) to the primary fuel tank module (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures
8. Install the fuel tank assembly. Refer to Fuel Tank Replacement Removal and Replacement.
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
10. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).