Fuel Tank Fuel Pump Module Replacement (Short Wheelbase)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5537615 Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) Single Use Fasteners and Components Fuel Sender Seal Special Tools CH–45722 Fuel Sender Lock Ring Wrench Equivalent regional tools: Special Tools

Warning

Refer to Diesel/Gasoline Vapors Warning.

Warning

Refer to Safety Glasses Warning. Removal Procedure

1. Relieve the fuel system pressure. Fuel Pressure Relief
2. Drain the fuel tank. Fuel Tank Draining
3. Raise and support the vehicle. Lifting and Jacking the Vehicle

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 1

4. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Remove [4x]
5. Remove both rear stabilizer shaft clamp  (2) from the frame and let the stabilizer shaft hang.

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 2

6. Evaporative Emission Hose (1) » Disconnect [2x] — Plastic Collar Quick Connect Fitting Service

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 3

Note

Components removed for clairity.

7. Fuel Feed Hose (1) @ Fuel Feed Pipe (2) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 4

8. Fuel Tank Filler Hose Clamp (1) » Loosen
9. Fuel Tank Filler Hose (2) » Remove
10. Evaporative Emission Hose (3) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 5

11. Fuel Tank Filler Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 6

12. Place a suitable adjustable jack under the fuel tank.
13. Strap fuel tank to jack.
14. Fuel Tank Strap Bolt (1) » Remove [2x]
15. Fuel Tank Strap (2) » Remove [2x]

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 7

16. Lower the fuel tank, allowing clearance to access connections at the top of the tank.
17. Electrical Connector (1) » Disconnect [3x]
18. Fuel Feed Hose Clip (2) » Disengage
19. Wiring Harness Retainer (3) » Disengage

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 8

20. Fuel Tank (1) » Remove

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 9

21. Evaporative Emission Canister Vent Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
22. Evaporative Emission Canister Vent Hose (2) » Reposition

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 10

23. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Disengage [2x]
24. Fuel Feed Hose @ Fuel Tank Fuel Pump Module (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
25. Fuel Feed Hose (2) » Reposition

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 11

26. Fuel Tank Filler Vent Hose @ Fuel Tank Fuel Pump Module (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
27. Fuel Tank Filler Vent Hose (2) » Reposition away

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 12

28. Fuel Sender Retainer (1) » Remove — CH–45722 Fuel Sender Lock Ring Wrench(2)

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 13

29. Fuel Tank Vent Valve Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Tank Fuel Pump Module Replacement (Short Wheelbase) — figure 14

30. Fuel Tank Fuel Pump Module (1) » Remove

31. Disconnect the Vent Hose inside the canister

32. Fuel Sender Seal (2) » Remove and DISCARD Installation Procedure

33. Fuel Sender Seal (2) » Install NEW

34. Fuel Tank Fuel Pump Module (1) » Install

35. Connect the Vent Hose inside the canister

36. Fuel Tank Vent Valve Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

37. Fuel Sender Retainer(1) » Install — CH–45722 Fuel Sender Lock Ring Wrench(2)

38. Fuel Tank Filler Vent Hose (2) » Reposition

39. Fuel Tank Filler Vent Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

40. Fuel Feed Hose (2) » Reposition

41. Fuel Feed Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

42. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Engage [2x]

43. Evaporative Emission Canister Vent Hose (2) » Reposition

44. Evaporative Emission Canister Vent Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

45. Place a suitable adjustable jack under the fuel tank.

46. Strap fuel tank to jack.

47. Raise the fuel tank  (1), allowing clearance to access connections at the top of the tank.

48. Wiring Harness Retainer (3) » Engage

49. Fuel Feed Hose Clip (2) » Engage

50. Electrical Connector (1) » Connect [3x]

51. Raise the tank to the installed position.

52. Fuel Tank Strap (2) » Install [2x]

Caution

Refer to Fastener Caution.

21. Fuel Tank Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications

22. Fuel Tank Filler Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

23. Evaporative Emission Hose (3) » Connect — Plastic Collar Quick Connect Fitting Service

24. Fuel Tank Filler Hose (2) » Install

25. Fuel Tank Filler Hose Clamp (1) » Tighten — Fastener Specifications

26. Fuel Feed Hose (1) @ Fuel Feed Pipe (2) » Connect — Plastic Collar Quick Connect Fitting Service

27. Evaporative Emission Hose (1) » Connect [2x] — Plastic Collar Quick Connect Fitting Service

28. Raise rear stabilizer shaft into installed position.

29. Rear Stabilizer Shaft Clamp (2) » Install [2x]

30. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Install and tighten [4x] — Fastener Specifications

31. Lower the vehicle.

32. Refill the fuel tank.

33. Inspect for fuel leaks.