Fuel Sender Assembly Replacement

Fuel Sender Assembly Replacement

Tools Required

J 45722 Fuel Sender Lock Ring Wrench

Removal Procedure




1. Remove the fuel tank.
2. Disconnect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) from the fuel pressure sensor and the module.




3. Disconnect the fuel tank vent pipe quick connect fittings (3, 4) from the module.



4. Install the J 45722 to the fuel pump module lock ring.






Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

5. Using the J 45722 and a long breaker-bar, rotate the lock ring in a counterclockwise direction in order to unlock the lock ring.




6. Remove the J 45722 from the fuel pump module lock ring.
7. Lift the fuel pump module up slightly in order to disconnect the fuel tank vent pipe quick connect fitting (1) from the module cover. Refer to Plastic Collar Quick Connect Fitting Service.




8. Raise the fuel pump module up from the fuel tank. Tilt the module in order to allow the fuel level sensor arm and float to clear the module opening.
9. Remove the fuel pump module.
10. Remove and discard the fuel pump module seal.
11. Clean the fuel pump module sealing surfaces.

Installation Procedure

Caution: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.

Important:
* Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.

* Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW fuel pump module.

* Inspect the lock ring for flatness as best as possible. If the lock ring is warped, replace the fuel pump module.




1. Clean any contamination from the male pipe ends of the fuel pump module.
2. Place a NEW fuel tank module seal onto the fuel tank.
3. Insert the fuel pump module into the fuel tank allowing the sensor arm and float to clear the module opening.
4. Lower the module down into the fuel tank until the fuel tank vent pipe quick connect fitting can be connected.




5. Connect the fuel tank vent pipe quick connect fitting (1) at the module cover.
6. Press the fuel tank module downward.




7. Install the J 45722 to the fuel pump module lock ring.






Important: Ensure that the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

8. Using the J 45722 and a long breaker-bar, rotate the lock ring in a clockwise direction in order the lock the lock ring.
9. Remove the J 45722 from the fuel pump module lock ring.




10. Connect the fuel tank vent pipe quick connect fittings (3, 4) to the module.



11. Connect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) to the fuel pressure sensor and the module.
12. Install the fuel tank.