Fuel Tank Unit: Service and Repair

Fuel Sender Wrench:

SPECIAL TOOL(S)

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.

1. Drain the fuel tank.

NOTE: It is not necessary to remove the fuel tank to carry out this procedure. The Fuel Delivery Module can be accessed under the RH rear seat bottom and access cover.

2. Raise and support the vehicle.







3. Remove the bolts and the nuts and position the exhaust heat shield on the exhaust system.







4. Loosen the right support strap approximately one inch.







5. Loosen the left support strap approximately one inch.
6. Lower the hoist.







7. Disconnect the electrical connector.







8. Disconnect the module fuel line connectors.
1 Press the release tabs on the module fitting.
2 Turn the fuel line slightly and pull straight up to remove the fuel line connector.

NOTE: Make sure the fuel line connector is fully seated prior to compressing the release tabs.







9. Install the special tool and loosen the lockring retainer nut.
10. Continue removing the lockring retainer nut by hand.







11. Lift up on the module top flange and position it aside.







12. Remove the fuel delivery module.
1 Press the lock tabs and release the module from the tank retainer cup.
2 Remove the module from the tank.

CAUTION: The fuel module must be handled carefully to avoid damage to the float arm and the filter during removal.

NOTE: The module will contain some residual fuel. Lift straight up and out of the retainer cup and tilt while in tank (float side down) to drain some fuel out of the reservoir. Then straighten and lift straight up and out of the tank. Drain excess fuel into suitable container.

INSTALLATION
1. To install, reverse the removal procedure.

NOTE: New module assembly flange gaskets must be used. Gently position the module seal by hand and make sure it remains in position during installation. Align the module with the in-tank retaining cup and push down on the module until the latches snap into position onto the cup. Make sure the fuel line tube connectors are fully seated into the outlet connector fittings.