Fuel Tank Fuel Pump Module Replacement (Long Wheelbase)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5598939 Fuel Tank Fuel Pump Module Replacement (Long Wheelbase) Single Use Fasteners and Components Fuel Sender Seal Fuel Tank Filler Vent Hose Strap [2x] 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 (Long 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 (Long Wheelbase) — figure 2

6. Evaporative Emission Canister Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
7. Evaporative Emission Canister Filter Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
8. Fuel Feed Hose (3) » Disconnect — Plastic Collar Quick Connect Fitting Service

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

9. Evaporative Emission Canister Solenoid (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
10. Fuel Tank Filler Hose Clamp (2) » Loosen
11. Fuel Tank Filler Hose (3) » Remove
12. Fuel Tank Filler Vent Hose (4) » Disconnect — Plastic Collar Quick Connect Fitting Service

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

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

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

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

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

21. Fuel Tank (1) » Remove
22. Remove strap retaining fuel tank to jack.

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

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

24. Fuel Tank Filler Vent Hose (1) » Disconnect @ Fuel Tank Fuel Pump Module — Plastic Collar Quick Connect Fitting Service
25. Fuel Tank Filler Vent Hose (1) » Reposition

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

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

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

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

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

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

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

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

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

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

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

35. Fuel Sender Seal (2) » Install NEW

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

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

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

39. Fuel Feed Hose (2) » Install

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

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

42. Evaporative Emission Canister Vent Hose (2) » Install

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

44. Fuel Tank Filler Vent Hose (1) » Install

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

46. Tape (1) » Install

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

48. Strap fuel tank to jack.

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

50. Wiring Harness Retainer (3) » Engage [2x]

51. Fuel Feed Hose Clip (2) » Engage

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

53. Raise the tank to the installed position.

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

Caution

Refer to Fastener Caution.

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

22. Remove strap retaining fuel tank to jack.

23. Fuel Tank Filler Vent Hose (4) » Connect — Plastic Collar Quick Connect Fitting Service

24. Fuel Tank Filler Hose (3) » Install

25. Fuel Tank Filler Hose Clamp (2) » Tighten — Fastener Specifications

26. Evaporative Emission Canister Solenoid (1) » Connect — Plastic Collar Quick Connect Fitting Service

27. Fuel Feed Hose (3) » Connect — Plastic Collar Quick Connect Fitting Service

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

29. Evaporative Emission Canister Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

30. Raise rear stabilizer shaft into installed position.

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

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

33. Lower the vehicle.

34. Refill the fuel tank.

35. Inspect for fuel leaks.