Secondary Fuel Tank Module Replacement

Secondary Fuel Tank Module Replacement

Special Tools

CH-48482 - 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).

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 Service and Repair.

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.


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.




6. Disconnect the electrical harness connector (2) from the secondary fuel tank module (1).





Note: The cam lock ring is a single use item and must be replaced after it was removed.

7. Remove the cam lock ring (2) from the secondary fuel tank module (3) by rotating the cam lock ring (2) counter-clockwise using the fuel tank sender wrench CH-48482 - fuel tank sender wrench (1).

8. Discard the cam lock ring (2).





Note:

* To release the transfer tube (4) from the secondary fuel tank module (1), squeeze the releasing buttons (5) on the transfer tube (4).

* Note the orientation of the secondary fuel tank module (1) in relation to the fuel tank assembly (2).

* Do not damage the fuel level sensor float rod (3) when removing the secondary fuel tank module (1) from the fuel tank.

9. Carefully lift the secondary fuel tank module (1) from the fuel tank assembly (2), enough to disconnect the transfer tube (4) from the secondary fuel tank module (1).

10. Disconnect the transfer tube (4) from the secondary fuel tank module (1).

11. Carefully manoeuvre the secondary fuel tank module (1) from the fuel tank assembly (2).




12. Remove the fuel tank seal (1) from the fuel tank assembly (2).

13. Discard the fuel tank seal (1).

Installation Procedure




1. Install a NEW fuel tank seal (1) to the fuel tank assembly (2).





Note: Do not damage the fuel level sensor float rod (3) when installing the secondary fuel tank module (1).

2. Carefully install the secondary fuel tank module (1) into the fuel tank (2), enough to connect the transfer tube (4) to the secondary fuel tank module (1).

Note: Listen for an audible click to confirm the correct installation of the transfer tube connector (4) to the secondary fuel tank module (1).

3. Connect the transfer tube (4) to the secondary fuel tank module (1).

4. Carefully manoeuvre and install the secondary fuel tank module (1) to the fuel tank assembly (2).





Note: Apply suitable pressure onto the secondary fuel tank module (3) to hold the secondary fuel tank module (3) in position while installing the NEW cam lock ring (2).

5. Install a NEW cam lock ring (2) to the secondary fuel tank module (3) by rotating the cam lock ring (2) clockwise using the fuel tank sender wrench CH-48482 - fuel tank sender wrench (1).





Note: Listen for an audible click to confirm the correct installation of the electrical harness connector (2) to the secondary fuel tank module (1).

6. Connect the electrical harness connector (2) to the secondary fuel tank module (1).

7. Install the fuel tank assembly to the vehicle. Refer to Fuel Tank Replacement Removal and Replacement.

8. Lower the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

9. 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).