For 1990-2009 cars

#### Special Tools

J 45722 Fuel Sender Lock Ring Wrench

### Removal Procedure

Warning: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

Caution: Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

Note: A NEW fuel tank module seal is necessary each time the fuel tank module is serviced. Obtain a NEW seal prior to beginning this service procedure.

1. Remove the fuel tank. Refer to Fuel Tank Replacement.
2. Disconnect the fuel pump fuel feed line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
3. Disconnect evaporative emission (EVAP) canister vent front pipe quick connect fitting (4) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
4. Reposition the fuel pump fuel feed line and the EVAP canister vent front pipe out of the way.
5. Disconnect the fuel sender wiring harness electrical connector (2) from the fuel tank pressure sensor.
6. Disconnect the fuel sender wiring harness electrical connector (3) from the fuel tank module.

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

7. Install the J 45722 (1) to the fuel tank module lock ring.

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.

8. Using the J 45722 and a long breaker-bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring.
9. Remove the J 45722 .

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.

10. Remove the fuel tank module lock ring (1).
11. Slowly raise the module (2) until the fuel level sensor float arm is just visible.

Note: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

12. Tilt the module towards the lower front corner of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the fuel tank.
13. Carefully discard the fuel in the module reservoir bucket into an approved container.
14. Remove and discard the fuel tank module seal (3).
15. Remove the fuel level sensor, if required. Refer to Fuel Level Sensor Replacement.

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.

16. 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.
17. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
18. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

### Installation Procedure

1. Install the fuel level sensor, if required. Refer to Fuel Level Sensor Replacement.
2. Install a NEW fuel tank module seal (3) onto the fuel tank.

Note: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor bloat arm.

3. Tilt the module towards the lower front corner of the fuel tank to allow the level sensor float arm to clear the tank opening. Install the module into the fuel tank.
4. Position and install the fuel tank module lock ring (1).
5. Install the J 45722 to the fuel tank module lock ring.
6. Using the J 45722 and a long breaker-bar, rotate the lock ring clockwise locking the fuel tank module lock ring.
7. Remove the J 45722 (1) from the fuel tank module lock ring.
8. Connect the fuel sender wiring harness electrical connector (3) to the fuel tank module.
9. Connect the fuel sender wiring harness electrical connector (2) to the fuel tank pressure sensor.
10. Position the fuel pump fuel feed line and the EVAP canister vent front pipe to the fuel tank.
11. Connect EVAP canister vent front pipe quick connect fitting (4) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
12. Connect the fuel pump fuel feed line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
13. Install the fuel tank. Refer to Fuel Tank Replacement.