Fuel Tank Fuel Pump Module Replacement - Left Side LS3, LS7

Special Tools

J39765-A Fuel Sender Lock Ring Tool

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the left fuel tank. Refer to Fuel Tank Replacement - Left Side.
3. Place the fuel tank on a suitable work surface.



4. Disconnect the fuel pump jumper harness from the fuel pump module (1).
5. Disconnect the jet line insert connector from the crossover tube to fuel tank opening.
6. Disconnect the fuel feed line from the welded clip on the side of the fuel tank.

Important: The fuel pump module is spring loaded and will spring upward when the locking ring is removed.

7. Using the J39765-A , remove the fuel pump module locking ring.



8. Carefully remove the fuel pump module from the fuel tank, with the jet lines connected. Take care not to damage the fuel sender float arm.
9. Disconnect the jet line quick-connect connectors from the fuel pump module inner port.
10. Remove the jet line from the module retainer cup. This line has no attached connector.
11. Remove the fuel pump module O-ring from the fuel tank opening.
12. Remove the jet line insert through the crossover tube to fuel tank opening.

1. Inspect the jet line insert for damage and replace if necessary.
2. Install the jet line insert through the crossover tube to fuel tank opening.
3. Install a new fuel pump module O-ring to the fuel tank opening.
4. Place tape around the jet line with the connector. This will permit line access once the pump module is inserted into the fuel tank.



5. Install the pump module into the fuel tank half way , taking care not to damage the float arm.
6. Using the tape as a guide, gently pull the jet line up through the fuel pump module opening.
7. Place the jet line with no connector in the module retainer cup.
8. Secure the line into the module retaining clip.
9. Remove the tape from the jet line with a connector.

Important: Pull on each connector to ensure that the connectors are properly latched.

10. Connect the jet line quick-connect connectors to the fuel pump module inner port.
11. Compress and align the fuel pump module into the fuel tank, while taking care not to damage the float arm.
12. Install the fuel pump module lock ring.
13. Using the J39765-A , fully lock the fuel pump module lock ring in place.
14. Connect the fuel supply line into the weld clip on the side of the fuel tank.
15. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading.

Resistance

•	Empty tank reading 247-253 ohms resistance

•	Full tank reading 38.5-41.05 ohms resistance

Important: Pull the jet line insert connector to ensure that the insert is properly attached.

16. Connect the jet line insert connector into the crossover tube to fuel tank opening.



17. Connect the fuel pump jumper harness to the fuel pump module (1).
18. Install the left fuel tank. Refer to Fuel Tank Replacement - Left Side.
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

Fuel Tank Fuel Pump Module Replacement - Left Side LS9

Special Tools

J-39765-A Fuel Sender Lock Ring Tool

1. Remove the left fuel tank. Refer to Fuel Tank Replacement - Left Side.
2. Disconnect the jet line insert connector (1) from the crossover tube to fuel tank opening.
3. Disconnect the fuel feed line (2) from the welded clip on the side of the fuel tank.




Note: The fuel pump module is spring loaded and will spring upward when the locking ring is removed.

4. Using the J-39765-A ring , turn the fuel pump module locking ring (1) counterclockwise.



5. Partially raise the fuel pump module from the fuel tank, and disconnect the fuel supply line (1) refer to Plastic Collar Quick Connect Fitting Service.



6. Reach into the tank and remove the fuel return line (1).



7. Remove the fuel tank module (1) and O-ring (2).

1. Inspect the jet line insert for damage and replace if necessary.
2. Install a new fuel pump module O-ring to the fuel tank opening.



3. Loop string around the fuel supply line (1) and the fuel return line (2) and lower them into the tank.



4. With the aid of an assistant, partially lower the fuel sender assembly into the tank and connect the fuel supply line (1).
5. Remove the looped string from the supply line.



6. With the aid of an assistant, use a Snap-on soft grip trim tool ASG187B or equivalent in order to insert the return line (1) into the module retainer cup.
7. Remove the looped string from the return line.



8. Compress and align the fuel pump module into the fuel tank.
9. Install the fuel pump module lock ring.
10. Using the J-39765-A ring , fully lock the fuel pump module lock ring in place by rotating clockwise.



11. Connect the fuel feed line (2) to the welded clip on the side of the fuel tank.
12. Connect the jet line insert connector (1) to the crossover tube fuel tank opening.
13. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading.

Resistance

•	Empty tank reading 247-253 ohms resistance

•	Full tank reading 38.5-41.05 ohms resistance

14. Install the left fuel tank. Refer to Fuel Tank Replacement - Left Side.