Fuel Tank Unit: Service and Repair

Fuel Sender Assembly Replacement


REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 34730-1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench
^ J 42960-1 Fuel Tank Drain Hose
^ J 42960-2 Fuel Flapper Door Holder

CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Remove the fuel tank.
5. Disconnect the fuel feed pipe (4), the fuel return pipe (2), and the [1][2]EVAP pipe (3) from the fuel sender.




6. Disconnect the fuel sender electrical connectors (1) from the fuel sender.
7. Remove the fuel sender assembly retaining ring using the J 39765 Fuel Sender Lock Nut Wrench.

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.




8. Remove the fuel sender assembly.

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.




9. Remove the fuel sender seal.
10. Discard the fuel sender seal.
11. Clean the seal sealing surfaces.

INSTALLATION PROCEDURE

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. Install the new fuel sender seal on the fuel tank.

IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.




2. Install the fuel sender assembly into the fuel tank.




3. Install the fuel sender assembly retaining ring using the J 39755 Fuel Sender Lock Nut Wrench.




4. Connect the fuel sender electrical connectors (1) to the fuel sender.
5. Connect the fuel feed pipe (4). the fuel return pipe (2), and the [1][2]EVAP pipe (3) to the fuel sender.
6. Install the fuel tank.
7. Refill the fuel tank.
8. Install the fuel filler cap.
9. Connect the negative battery cable.
10. Inspect for leaks
10.1. Turn the Ignition switch ON for 2 seconds.
10.2. Turn the Ignition switch OFF for 10 seconds.
10.3. Turn the Ignition switch ON.
10.4. Check for fuel leaks.
11. Perform the Idle learn procedure. Refer to PCM Idle Learn Procedure.