Captiva

Fuel Tank Fuel Pump Module Replacement

Special Tools

CH 45722 Fuel Sender Lock Ring Wrench

For equivalent regional tools, refer to Special Tools .

Caution: 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 tab with penetrating oil prior to attempting removal.

1. Remove the secondary fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement - Secondary .
2. Disconnect the fuel feed line quick connect fitting (1) from the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .
3. Open the retaining clip (3) on the fuel tank and remove the fuel feed line (2).



4. Disconnect the engine wiring harness electrical connectors (2) from the fuel tank fuel pump primary module and the fuel tank pressure sensor.
5. Disconnect the vapour line quick connect fittings (1) from the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .



6. Install theCH 45722 spanner (1) to the fuel tank fuel pump module lock ring.




Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

Note: 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.

7. Using the CH 45722 spanner and a long breaker bar, rotate the lock ring anticlockwise unlocking the fuel tank fuel pump module lock ring.



8. Remove the CH 45722 spanner (1).



9. Remove the fuel tank fuel pump module lock ring (1).

Caution: 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.

10. Slowly raise the module (2) until the fuel level sensor float arm is just visible.

Note: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

11. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
12. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.

Note: DO NOT reuse the old fuel tank module O-ring seal.

13. Remove and discard the fuel tank fuel pump module O-ring seal (3).
14. If replacing the fuel tank fuel pump module, remove the fuel level sensor, if required. Refer to Fuel Level Sensor Replacement .




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.

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

•	Check the lock ring for flatness.

15. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
16. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
17. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. If the fuel tank fuel pump module was replaced, install the fuel level sensor, if required. Refer to Fuel Level Sensor Replacement .
2. Install a NEW fuel tank module O-ring seal (3) onto the fuel tank.
3. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
4. Lower the module assembly (2) into the tank.
5. Position and install the fuel tank module lock ring (1).



6. Install the CH 45722 spanner to the fuel tank fuel pump module lock ring.




Note: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.

Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
7. Use the CH 45722 spanner and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring.



8. Remove the CH 45722 spanner (1) from the fuel tank fuel pump module lock ring.



9. Connect the vapour line quick connect fittings (2) to the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .
10. Connect the engine wiring harness electrical connectors (1) to the fuel tank fuel pump primary module and the fuel tank pressure sensor.



11. Lay the fuel feed line (2) into position and connect the fuel feed line quick connect fitting (1) to the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .
12. Close the retaining clip (3) on the fuel tank.
13. Install the secondary fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement - Secondary .