Fuel Tank Module Replacement Short Wheel Base

Special Tools

J-45722 Fuel Sender Lock Nut Wrench

Caution: 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.

1. Remove the fuel tank. Refer to Fuel Tank Replacement.
2. Disconnect the fuel tank harness electrical connectors (4) from the module.
3. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
4. Disconnect the fuel feed pipe quick connect fitting (3) from the module. Refer to Plastic Collar Quick Connect Fitting Service.
5. Disconnect the evaporative emission (EVAP) pipe quick connect fittings (5, 6) from the module. Refer to Plastic Collar Quick Connect Fitting Service.




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

Caution: 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.

Note: 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.

6. Use the J-45722 Wrench and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.

Warning: 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

7. Remove the fuel tank module and seal from the fuel tank.
8. Discard the fuel tank module seal.
9. Clean the fuel tank module sealing surfaces.




Note: 

•	Some lock ring 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. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
11. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
12. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

Warning: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Position a NEW fuel tank module seal (2) onto the fuel tank.

Note: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, ensure that the fuel pump strainer does not block full travel of float arm.

2. Install the module into the fuel tank.




Note: 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.
3. Use the J-45722 Wrench in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
4. Connect the EVAP pipe quick connect fittings to the module. Refer to Plastic Collar Quick Connect Fitting Service.
5. Connect the fuel feed pipe quick connect fitting to the module. Refer to Plastic Collar Quick Connect Fitting Service.
6. Connect the fuel tank harness electrical connectors to the module.
7. Install the fuel tank. Refer to Fuel Tank Replacement.

Fuel Tank Module Replacement Long Wheel Base

Special Tools

J-45722 Fuel Sender Lock Nut Wrench

Caution: 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.

1. Remove the fuel tank. Refer to Fuel Tank Replacement.
2. Disconnect the fuel tank harness electrical connectors (3) from the fuel tank module.
3. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
4. Disconnect the fuel feed pipe quick connect fitting (4) from the module. Refer to Plastic Collar Quick Connect Fitting Service.
5. Disconnect the evaporative emission (EVAP) pipe quick connect fittings (5, 6) from the module. Refer to Plastic Collar Quick Connect Fitting Service.




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

Caution: 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.

Note: 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.

6. Use the J-45722 Wrench and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.

Warning: 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

7. Remove the module and seal from the fuel tank.
8. Discard the module seal.
9. Clean the module sealing surfaces.




Note: 

•	Some lock ring 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. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
11. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
12. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

Warning: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Position a NEW fuel tank module seal (7) on the fuel tank.

Note: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel tank module assembly, as this will restrict fuel flow. Also, ensure that the fuel pump strainer does not block full travel of float arm.

2. Install the fuel tank module (2) into the fuel tank.




Note: Always replace the fuel tank module seal when installing the fuel tank module 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.
3. Use the J-45722 Wrench in order to install the fuel tank module lock ring. Turn the fuel sender lock ring in a clockwise direction.
4. Connect the EVAP quick connect fittings to the module. Refer to Plastic Collar Quick Connect Fitting Service.
5. Connect the fuel feed pipe quick connect fitting to the module. Refer to Plastic Collar Quick Connect Fitting Service.
6. Connect the fuel tank harness electrical connectors to the fuel tank module.
7. Install the fuel tank. Refer to Fuel Tank Replacement.