Rendezvous 2006-2007

Fuel Pump

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Removal & Installation



3.4L & 3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Do NOT pick up the fuel pump by the fuel pipes. Doing this could cause the joints to be damaged.



    Negative battery cable
     
    Fuel tank
     
    Fuel Evaporative Emission (EVAP) pipes.
     
    Fuel sender shield
     
    Quick connect fittings at the fuel pump
     
    Fuel Tank Pressure (FTP) electrical connector
     
    Fuel pump assembly lockring
     



    Fuel pump assembly from the fuel tank and discard the O-ring
     

  6.  

To install:

  1. Install or connect the following:

    New O-ring on the fuel tank
     
    Fuel pump into the fuel tank making certain not to fold or twist the strainer and that it does not interfere with the full travel of the float arm
     
    Fuel pump locking nut
     
    Quick connect fittings at the fuel pump
     
    FTP sensor electrical connector
     
    Fuel Evaporative Emission (EVAP) pipes.
     
    Fuel sender shield
     
    Fuel tank and fill the tank
     
    Negative battery cable
     

  2.  
  3. Prime the fuel system as follows:
    1. Turn the ignition switch ON for two seconds.
    2.  
    3. Turn the ignition switch OFF for 10 seconds.
    4.  
    5. Turn the ignition switch ON and checks for leaks. Repair if necessary.
    6.  

  4.  

3.6L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system fuel pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Raise the vehicle.
  8.  
  9. Disconnect the fuel tank wiring harness connector.
  10.  
  11. Disconnect the Fuel Evaporative Emission (EVAP) pipes.
  12.  
  13. Remove the EVAP canister bracket nut.
  14.  
  15. Loosen the fuel tank fill pipe hose clamp.
  16.  
  17. Disconnect the fuel tank fill pipe hose from the fuel tank.
  18.  
  19. Disconnect the EVAP vent pipe near the fill pipe hose.
    NOTE
    Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

  20.  
  21. With the aid of an assistant or a transmission jack, support the fuel tank and remove the fuel tank strap attaching bolts.
  22.  
  23. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
  24.  
  25. Disconnect the fuel sender module electrical connectors.
    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.

  26.  
  27. Disconnect the fuel pipes from the fuel sender.
    NOTE
    Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.


    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.

  28.  
  29. Use tool J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the lock ring in a counterclockwise direction.
  30.  
  31. Remove the fuel sender lock ring and the fuel sender from the fuel tank.
  32.  
  33. Remove and discard the fuel sender seal.

    Click image to see an enlarged view

    Fig. Fuel pump module-with 3.6L engine

  34.  
  35. Remove the fuel level sensor from the fuel sender module.
    NOTE
    Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.


    NOTE
    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.



    Click image to see an enlarged view

    Fig. Measuring lock ring for flatness-with 3.6L engine

  36.  
  37. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feelergauge at 7 points.
  38.  
  39. If warpage is less than 0.41 mm (0.016 in.), the lock ring does not require replacement. If warpage is greater than 0.41 mm (0.016 in.), the lock ring must be replaced.
  40.  

To install:

  1. Install the fuel level sensor to the fuel sender module.
  2.  
  3. Clean the fuel sender sealing flange.
    NOTE
    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 to the seal groove.

  4.  
  5. Install the NEW fuel sender seal to the fuel tank seal groove.
  6.  
  7. Install the fuel sender and the fuel sender lock ring.
  8.  
  9. Use tool J 45722 in order to install the fuel sender lock ring. Turn the lock ring in a clockwise direction.
  10.  
  11. Install the fuel pipes to the fuel sender.
  12.  
  13. Install the fuel sender sensor electrical connectors.
  14.  
  15. Install the EVAP canister.
  16.  
  17. Install the EVAP vent solenoid valve.
  18.  
  19. Install the fuel pipes to the fuel tank.
  20.  
  21. Install the fuel tank wiring harness to the fuel tank.
  22.  
  23. Install the fuel sender.
  24.  
  25. With the aid of an assistant or a transmission jack, position and support the fuel tank.
    NOTE
    Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

  26.  
  27. Install the fuel tank strap bolts. Tighten the fuel tank strap bolts to 35 ft. lbs. (47 Nm).
  28.  
  29. Install the EVAP canister bracket nut. Tighten the EVAP canister bracket nut to 53 inch lbs. (6 Nm).
  30.  
  31. Install the EVAP vent pipe near the fill pipe hose.
  32.  
  33. Install the fuel tank filler pipe hose to the fuel tank. Tighten the fuel tank filler pipe hose clamp to 22 inch lbs. (2.5 Nm).
  34.  
  35. Connect the fuel pipes.
  36.  
  37. Install the fuel tank wiring harness connector.
  38.  
  39. Lower the vehicle.
  40.  
  41. Add fuel as necessary and install the fuel tank filler pipe cap.
  42.  
  43. Inspect for fuel leaks. Perform the following steps:

    Turn ON the ignition for 2 seconds.
     
    Turn OFF the ignition for 10 seconds.
     
    Turn ON the ignition.
     
    Inspect for fuel leaks.
     

  44.  

 
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