Equinox 2005-2007, Torrent 2006-07

Fuel Pump

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Removal & Installation



Primary Module

WARNING
NEW fuel tank module seals are necessary each time the fuel tank module is serviced. Obtain NEW seals for both the primary and secondary modules prior to beginning this service procedure.


CAUTION
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.


NOTE
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.  
  3. Remove the secondary fuel pump module.
  4.  
  5. Disconnect the electrical connectors from the primary fuel pump module and fuel tank pressure sensor.
    NOTE
    Avoid damaging the lock ring. Use only tool J-45722 to prevent damage to the lock ring.


    NOTE
    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.


    WARNING
    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.



    Click image to see an enlarged view

    Fig. Tool J-45722



    Click image to see an enlarged view

    Fig. Primary fuel tank module

  6.  
  7. Use tool J 45722, or equivalent and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.
  8.  
  9. Disconnect the fuel feed and vent lines from the fuel tank.
    NOTE
    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 45 degrees.

  10.  
  11. Remove the primary fuel pump module assembly.
    WARNING
    Always replace the fuel pump module-to-tank seal, O-ring, when the fuel pump module is removed.

  12.  
  13. Discard the fuel pump module-to-tank seal.
    WARNING
    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.


    WARNING
    Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.


    WARNING
    Check the lock ring for flatness.

  14.  
  15. 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. If the warpage is less than 0.41 mm (0.016 in.), the lock ring does not require replacement. If the warpage is greater than 0.41 mm (0.016 in.), the lock ring must be replaced.
  16.  

To install:

  1. Insert the new primary fuel pump module assembly with the level sender and the new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
    WARNING
    Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.

  2.  
  3. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  4.  
  5. Use tool J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
  6.  
  7. Connect the wiring harness to the primary fuel pump module and fuel tank pressure sensor.
  8.  
  9. Install the secondary fuel pump module.
  10.  
  11. Install the fuel tank.
  12.  

Secondary Module
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    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.


    CAUTION
    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.


    NOTE
    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.

  2.  
  3. Remove the fuel tank.
  4.  
  5. Disconnect the EVAP vent line quick connect.
    NOTE
    To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar.

  6.  
  7. Use tool J39765-A and remove the fuel pump module retaining ring.
  8.  
  9. Disconnect the secondary level sensor electrical connector.
  10.  
  11. Disconnect the suction port attaching tube by pressing down on the tab (1).
    NOTE
    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 45 degrees.

  12.  
  13. Remove the secondary fuel pump module.
    WARNING
    Always replace the fuel pump module-to-tank seal, O-ring, when the fuel pump module is removed.

  14.  
  15. Discard the fuel pump module-to-tank seal.

    Click image to see an enlarged view

    Fig. Secondary fuel tank module

  16.  

To install:

  1. Connect the suction port
  2.  
  3. Insert the new secondary fuel pump module with the level sender and new fuel pump-to-tank seal.
  4.  
  5. Ensure the orientation tabs are aligned.
  6.  
  7. Use the tool to install the fuel pump lock ring.
  8.  
  9. Connect the EVAP line quick connect.
  10.  
  11. Install the fuel tank.
  12.  

 
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