Secondary Fuel Tank Module Replacement

Secondary Fuel Tank Module Replacement

Tools Required

* EN-48278 Fuel Tank Sender Wrench
* CH-48482 Fuel Tank Sender Wrench



Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution (Service Precautions) .
1. Remove the fuel tank. Refer to Fuel Tank Replacement (Service and Repair) .




2. Disconnect the secondary fuel tank module electrical connector (1).




3. Rotate the cam lock ring (1) counter-clockwise using the EN-48278 .

Important: The cam lock ring (1) is a single use part and therefore must be discarded after removal.


4. Remove the cam lock ring (1) from the fuel tank.





Important: The secondary fuel tank module (1) is vertical in the installed position, but pivots for removal.


5. Carefully lift the secondary fuel tank module (1) from the fuel tank only enough to access the transfer tube (2).




6. Remove the fuel supply tube (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
7. Remove the secondary fuel tank module (2) from the fuel tank.




8. Remove the secondary fuel tank module seal (1) from the secondary fuel tank module (2).
Do not reuse the seal.



Installation Procedure






Important: Make sure the seal bead is facing the fuel tank.


1. Place the NEW secondary fuel tank module seal (1) over the secondary fuel tank module (2).




2. Complete the following in order to connect the transfer tube (1) to the secondary fuel tank module (2).

1. Grasp the transfer tube (1) from inside the fuel tank.
2. Position the module (2) near the module opening.
3. Connect the transfer tube (1) to the module (2).


Important: Make sure the fuel level float is free from binding while inserting the module (2).


3. Carefully insert the secondary fuel tank module (2) into the fuel tank.
4. Press the secondary fuel tank module (2) downward, aligning the module to the encapsulated ring.
5. Position the cam lock ring to the fuel tank.




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




8. Connect the secondary fuel tank module electrical connector (1).
9. Install the fuel tank. Refer to Fuel Tank Replacement (Service and Repair) .