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Why is the ground tab missing off the top of the Chrysler fuel pump FG0232?

These new fuel pumps do not require a ground tab because the pump is now grounded internally. Previously, fuel pumps had a static tab to ground metal so static would not be a problem for metal filter housing. Now, the vehicle has static wire, but instead of the pump having a tab, it is grounded internally. Just tape up and tape back the separate ground wire on the vehicle. It does not need to be connected with new style pump.

Read more here.

Are the new fuel filter replacements now internally built into the fuel pump assembly? Why are they different and what has changed?

 

Not all fuel filters are internal or built into the pump assembly. Most fuel filters are still external and can be replaced separately. If a vehicle was built with an external filter, it will always have an external filter. If a vehicle was built with the filter built into the pump assembly (an internal filter), it will always be that way. There is no switching back and forth.

The vehicle models that have a filter in the pump are considered “lifetime of pump” filters and should not need replacement. These filters are not serviced separately.

Read more here.

What are the differences in fuel level sensor function between model years for some 2006 and 2007 General Motors passenger cars?

The 2006 version of some models has a float level sensor in which the fuel level increases when resistance increases. In 2007, General Motors changed the architecture of the cluster on some vehicles, making the gauge now work ‘backwards.’ Thus, if a fuel level sensor for a 2006 application is installed on a 2007 application, the gauge will read opposite – when the tank is full the gauge shows empty, and when the tank is empty the gauge shows full. The key to prevent this is to check your application. Make sure you are using the correct part for the correct year application.

 

What causes premature D-ring failure on Ford diesel injectors, and what are recommendations to resolve the issue?

Premature D-ring failure of Ford diesel injectors is usually caused by either a leaking ball tube O-ring or leakage between the ball tube and injector D-ring. In the case of a leaking ball tube O-ring, ball tube O-rings flatten and harden with age, allowing pressurized oil to escape past the ball tube O-ring – blasting the top of the injector D-ring. Installation damage to the injector D-ring from the ball tubes being misaligned can cause leakage between the ball tube and the injector D-ring. 
To resolve the issue, replace ball tubes and O-rings when installing injectors, ensure the ball tubes are properly aligned during injector installation, and use clean engine oil to lubricate the ball tubes prior to installation.