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 fuel and evaporative emission (EVAP) lines from the fuel tank module.
3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.

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

4. Remove the cam lock ring.




5. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fittings below the module cover.
6. Squeeze the quick connect fittings (1) in order to disengage them from the module cover. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
7. Remove the fuel tank module from the fuel tank.
8. Remove and discard the fuel tank module seal.




9. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.

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 lock ring.
- Check the lock ring for flatness.

10. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
11. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

INSTALLATION PROCEDURE




1. Install the NEW fuel tank module seal onto the fuel tank.
2. Position the fuel tank module part way into the fuel tank.
3. Connect the quick connect fittings (1) to the module cover.
4. Install the fuel tank module into the fuel tank.
5. Place the cam lock ring into position.




6. Rotate the cam lock ring clockwise using the J 45722 until fully seated.

IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.

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

7. Connect the fuel and EVAP lines to the fuel tank module.
8. Install the fuel tank.