For 1990-2009 cars

#### Tools Required

SA9156E Fuel Tank Lock Ring Remover

### Removal Procedure

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Notice: 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.

1. Remove the fuel tank.
2. Disconnect the fuel feed and return lines from the filter/pressure regulator.
3. Disconnect the fuel pump vapor line from the fuel tank vent pipe.

Notice: To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar.

4. Use the SA9156E and remove the fuel pump module retaining ring. A 1/2 in. breaker bar (approximately 18 inches long) will easily loosen and remove the lock ring.
5. To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 90 degrees clockwise until the fuel lines are facing the 1 o'clock position. 12 o'clock is front of tank.

Notice: Care must be taken not to bend or twist the fuel pump filter or sending unit float arm during removal or installation of the fuel pump module assembly. A damaged fuel pump filter restricts fuel flow to the pump and a bent sending unit arm will not provide accurate readings. Care must be taken to assure the pump module is not dropped. A dropped pump can dislodged internal parts creating a noisy and/or leakage condition.

6. Carefully lift the fuel pump module, with the sending unit, straight up from the fuel tank until the bottom of the pump module is very close to the fuel tank opening. Then tilt the pump module about 45 degrees toward the right side of the tank and simultaneously lift it up and out of the tank opening watching that the level sender float arm is not being bent.

Important: Always replace the fuel pump module to tank seal, O-ring whenever the assembly is removed. The correct seal is green in color. Do not use the older black seal.

Important: Inspect the fuel tank for metal chips/debris. Remove all contaminants and replace the in-line fuel filter before installing a new fuel pump assembly when debris is present.

7. Discard the fuel pump module to tank seal.

### Installation Procedure

Important: If a new fuel pump module is being installed, make sure that fuel level sender is installed on module BEFORE installing into fuel tank.

1. Inspect the fuel tank and clean the fuel tank seal groove of any foreign debris and install a new seal.

Important: The correct seal is green in color. Do not use the older black seal.

2. Verify that the float arm on the fuel level sender has not been bent by standing the fuel pump module on a flat, horizontal surface and measuring the distance from this surface and the bottom of the float. A 5/32 in. diameter drill can be used as a gage. The gage must freely pass between the float and the horizontal surface with no more than 1/16 in. clearance.

Important: If the float arm requires repositioning to meet the clearance specification, assure that any bending is performed at the 90 degree bend near the level sender. The short section of the float arm going into the level sender must be supported so that bending does not take place at the level sender.

3. Carefully install the fuel pump module with sending unit in the fuel tank by orienting the float to face the right side of the tank, tilting the pump module approximately 45 degrees, and loading the float arm and pump into the tank opening. Insert the pump module all the way down into the tank and then rotate 90 degrees counterclockwise to align the module orientation tabs with slots in the tank opening. Correctly oriented, the lines from the pump module will be facing the 10 o'clock position. 12 o'clock is the front of tank.

Important: The fuel pump retaining ring cannot be properly installed if the pump flange locator tabs are not aligned with the slots in the tank.

4. Install the retaining lock ring using the SA9156E .
5. Connect fuel pump vapor line to fuel tank vent pipe.
6. Connect the fuel feed and return lines to the filter/pressure regulator.
7. Position the fuel feed, fuel return, and EVAP canister purge line in the fuel tank retaining clip and snap shut.
8. Install the loose retainer clip around the fuel feed, return, and purge line at upsets and snap closed.
9. Install the fuel tank.
10. Perform the Service Bay Diagnostic Test for the evaporative emission system using the scan tool. This test will verify the integrity of the vapor handling areas of the fuel system. Refer to Service Stall System (SSS) user guide.