Montana SV6 (2006), Relay, Terraza, Uplander (2005-2007)

Fuel Pump/Sender

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the fuel tank into an approved container.
    WARNING
    Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.


    WARNING
    Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace the pipes.

  8.  
  9. Raise the vehicle.

    Click image to see an enlarged view

    Fig. Showing the fuel tank assembly and related components

  10.  
  11. Disconnect the fuel supply pipe (5) quick-connect fitting.
  12.  
  13. Disconnect the evaporative emission (EVAP) purge pipe (6) quick connect fitting at the EVAP canister.
  14.  
  15. Loosen the fuel tank filler pipe hose clamp.
  16.  
  17. Disconnect the fuel tank filler from the fuel tank.
  18.  
  19. Disconnect the vapor recirculation pipe from the filler tube.
  20.  
  21. Remove the fuel tank shield.
  22.  
  23. With the aid of an assistant, support the fuel tank.
  24.  
  25. Remove the fuel tank strap attaching bolts.
  26.  
  27. Disconnect the fuel sender and the fuel tank pressure (FTP) sensor electrical connectors at the body pass through.
  28.  
  29. Remove the fuel tank from the vehicle.
  30.  
  31. Remove the fuel sender assembly (3).

    Click image to see an enlarged view

    Fig. Identifying the fuel sender assembly

  32.  
  33. Disconnect the fuel sender electrical connections (3).
  34.  
  35. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
  36.  
  37. Disconnect the fuel supply pipe quick-connect fitting (4) at the fuel sender assembly.
  38.  
  39. Disconnect the evaporative emission (EVAP) pipe quick-connect fittings (5, 6) at the fuel sender assembly.
    CAUTION
    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.

  40.  
  41. Use the J 45722 fuel sender lock nut wrench 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.
    CAUTION
    Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.

  42.  
  43. Remove the fuel sender assembly (2) and the seal (7) from the fuel tank.
  44.  
  45. Discard the fuel sender assembly seal.
  46.  
  47. Clean the fuel sender assembly sealing surfaces.
    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.


    NOTE
    Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage. If the warpage is less than 0.41mm (0.016 in), the lock ring does not require replacement. If the warpage is greater than 0.41mm (0.016 in), the lock ring must be replaced.

  48.  

To install:


CAUTION
In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

  1. Position the new fuel sender assembly seal on the fuel tank.
    WARNING
    Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, ensure that the fuel pump strainer does not block full travel of float arm.

  2.  
  3. Install the fuel sender assembly into the fuel tank.
    WARNING
    Always replace the fuel sender seal when installing the fuel sender assembly. Do not apply any type of lubrication in the seal groove.

  4.  
  5. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  6.  
  7. Use the J 45722 fuel sender lock nut wrench or equivalent, in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
  8.  
  9. Connect the fuel supply pipe quick-connect fitting (4) at the fuel sender assembly.
  10.  
  11. Connect the EVAP quick-connect fittings at the fuel sender assembly.
  12.  
  13. Connect the fuel sender electrical connections. 
  14.  
  15. With the aid of an assistant, position and support the fuel tank.
  16.  
  17. Connect the fuel sender and the FTP sensor electrical connectors at the body pass through.
  18.  
  19. Install the fuel tank retaining strap attaching bolts and tighten the bolts to 35 ft. lbs. (47.5 Nm).
  20.  
  21. Install the fuel tank shield.
  22.  
  23. Connect the vapor recirculation pipe to the fuel fill pipe.
  24.  
  25. Connect the fuel tank filler pipe to the fuel tank.
  26.  
  27. Connect the fuel feed pipe quick connect fitting.
  28.  
  29. Connect the EVAP purge pipe quick connect fitting at the EVAP canister.
  30.  
  31. Lower the vehicle.
  32.  
  33. Fill the tank with gasoline.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.
  38.  
  39. Check for fuel leaks.
  40.  

 
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