Secondary Fuel Tank Module Replacement

Secondary Fuel Tank Module Replacement

Special Tools

CH-48482

Removal Procedure

1. Ignition OFF.
Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning) in Cautions and Notices.

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 of the secondary fuel tank module electrical connector to release the connector.

4. Disconnect the secondary fuel tank module electrical connector (1) from the secondary fuel tank module assembly.





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

5. Rotate the cam lock ring (2) counter-clockwise using CH-48482 (1).





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

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

6. Carefully lift the secondary fuel tank module (1) out of the fuel tank assembly only enough to access the transfer tube (2).
7. Disconnect the transfer tube (2) from the secondary fuel tank module (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
8. Carefully remove the secondary fuel tank module (1) from the fuel tank assembly.





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

9. Remove the secondary fuel tank module seal (1) from the fuel tank assembly.
10. Discard the secondary fuel tank module seal (1).

Installation Procedure




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





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

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

2. Carefully install the secondary fuel tank module (1) to the fuel tank assembly just enough to connect the transfer tube (2) to the secondary fuel tank module (1).

Note: Listen for an audible click to confirm the correct installation of the transfer tube (2) to the secondary fuel tank module (1).

3. Connect the transfer tube (2) to the secondary fuel tank module (1).
4. Carefully install the secondary fuel tank module (1) to the fuel tank assembly.





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

5. Install a NEW cam lock ring (2) to the fuel tank (3).
6. Rotate the NEW cam lock ring (2) clockwise using CH-48482 (1) until the NEW cam lock ring (2) is fully seated.





Note: Listen for an audible click to confirm the correct installation of the secondary fuel tank module electrical connector (1).

7. Connect the secondary fuel tank module electrical connector (1) to the secondary fuel tank module assembly.
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).