Primary Fuel Tank Module Replacement

Primary Fuel Tank Module Replacement

Special Tools

J 45722 .

Removal Procedure

1. Ignition OFF.
Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


Warning: Refer to Gasoline/Gasoline Vapors Warning (Service Precautions).

Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).

3. Remove the fuel tank assembly. Refer to Fuel Tank Replacement (Service and Repair).





Note: Press the release tab (4) of the electrical connector to release the connector.

Note: Press both release tabs on the fuel feed line connector (3) to release the connector.

4. Disconnect the electrical connector (1) from the primary fuel tank module (2).
5. Detach the fuel feed line connector (3) from the primary fuel tank module (2)





Note: The primary fuel tank module is spring loaded. Take care when loosening the cam lock ring.

6. Rotate the cam lock ring (2) counter-clockwise using the J 45722 (1).

Note: The cam lock ring (2) is a single use part and must be replaced.

7. Remove the cam lock ring (2) from the fuel tank assembly (3).
8. Discard the cam lock ring (2).





Note: Observe the orientation of the primary fuel tank module (1) in relation to the fuel tank assembly (2).

Note: Do not damage the fuel level sensor float rod when removing the primary fuel tank module (1) from the fuel tank assembly (2).

9. Carefully lift the primary fuel tank module (1) out of the fuel tank assembly (2) only enough to access the transfer tube (3).

Note: Press both release tabs on the transfer tube (3) to release the connector.

10. Disconnect the transfer tube (3) from the primary fuel tank module (1).
11. Carefully manoeuvre and remove the primary fuel tank module (1) from the fuel tank assembly (2).





Note: The primary fuel tank module seal (1) is a single use part and must be replaced.

12. Remove the primary fuel tank module seal (1) from the fuel tank assembly.
13. Discard the primary fuel tank module seal (1).

Installation Procedure




1. Install a NEW primary fuel tank module seal (1) to the fuel tank assembly.





Note: Listen for an audible click to confirm correct installation of the transfer tube (3).

2. Connect the transfer tube (3) to the primary fuel tank module (1).

Note: Observe the orientation of the primary fuel tank module (1) in relation to the fuel tank assembly (2).

Note: Do not to damage the fuel level sensor float rod when installing the primary fuel tank module (1) to the fuel tank assembly (2).

Note: Make sure the fuel level float is free from binding while inserting the primary fuel tank module (1).

3. Carefully install the primary fuel tank module (1) to the fuel tank assembly (2).





Note: The primary fuel tank module is spring loaded when installed in the fuel tank assembly. Apply suitable pressure to the primary fuel tank module while installing the NEW cam lock ring (2)

4. Install a NEW cam lock ring (2) to the fuel tank assembly (3).
5. Rotate the cam lock ring (2) clockwise using the J 45722 (1) until the NEW cam lock ring (2) is fully seated.





Note: Listen for an audible click to confirm correct installation of the electrical connector locking tab (4).

6. Connect the electrical connector (1) to the primary fuel tank module (2).

Note: Listen for an audible click to confirm correct installation of the fuel feed line connector (3).

7. Connect the fuel feed line connector (3) to the primary fuel tank module (2)
8. Install the fuel tank assembly. Refer to Fuel Tank Replacement (Service and Repair).
9. Lower the vehicle to the ground.
10. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).