Fuel Sender Assembly Replacement
TOOLS REQUIRED- J 34730-1A Fuel Pressure Gauge
- J 37088-A Tool Set, Fuel Line Quick Connect Separator
REMOVAL PROCEDURE (LEFT OR RIGHT)
1. Disconnect the negative battery cable.
CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Raise the vehicle. Refer to Vehicle Lifting.
CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.
4. Remove the rear wheel and tire assembly.
5. Clean all of the fuel connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
6. Drain the fuel tanks. Refer to Fuel Tank Draining Procedure (W/FFS)Fuel Tank Draining Procedure (W/O FFS).
7. Remove the fuel tank shield.
8. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
9. Disconnect the quick-connect fittings from the fuel sender.
10. Cap all of the fuel pipes.
11. Disconnect the fuel sender electrical connector.
12. Remove the fuel tank strap.
13. Support the fuel tank.
14. Remove the fuel sender attaching bolts.
15. Remove the float arm retaining clip and the float arm for the left fuel sender only.
16. Carefully remove the fuel sender with the gasket.
17. Clean the gasket sealing surfaces.
INSTALLATION PROCEDURE (RIGHT)
1. Inspect the fuel sender gasket for damage and replace if necessary.
IMPORTANT: Do not bend or twist the float arm.
2. Insert the float arm through the fuel tank opening.
3. The fuel sender may need to be rotated in order to facilitate the installation.
4. Align the fuel sender gasket tab (2) with the fuel sender cover mark (1).
5. Align the fuel sender cover mark (1) with the fuel tank mark.
6. Hand tighten the fuel sender attaching bolts until finger tight.
7. Tighten the fuel sender assembly attaching bolts in sequence.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the bolt to 7 N.m (62 lb in).
8. Connect the fuel sender fuel feed pipe (1) (from the jet pump to the left tank, and the fuel feed rear crossover pipe (2) from the left tank to the jet pump).
9. Connect the fuel sender electrical connector.
10. Install the fuel tank strap (3).
11. Install the fuel tank strap bolts (1, 2, 4).
Tighten
- Tighten the bolt (2) to 25 N.m (18 lb ft).
- Tighten the bolt (1) to 25 N.m (18 lb ft).
- Tighten the remaining bolts (4) to 25 N.m (18 lb ft).
12. Install the fuel tank shield (1).
13. Install the fuel tank shield mount bolt (2).
14. Install the fuel tank shield mount nut (3).
Tighten
- Tighten the fuel tank shield mount bolt to 25 N.m (18 lb ft).
- Tighten the fuel tank shield mount nut to 12 N.m (106 lb in).
15. Install the rear wheel and tire assembly.
16. Lower the vehicle.
17. Refill the fuel system.
18. Install the fuel filler cap.
19. Connect the negative battery cable.
20. Perform the following procedure in order to inspect for leaks:
20.1. Turn the ignition switch ON for 2 seconds.
20.2. Turn the ignition switch OFF for 10 seconds.
20.3. Turn the ignition switch ON.
20.4. Inspect for fuel leaks.
21. Program the transmitters. Refer to Transmitter Programming in Keyless Entry.
INSTALLATION PROCEDURE (LEFT)
1. Install fuel pump strainer in the same position as noted during disassembly. Push on the outer edge of the strainer ferrule until the strainer is fully seated.
2. Install a sender gasket on the fuel sender.
3. Insert the fuel sender through the fuel tank opening.
4. The fuel sender may need to be rotated in order to facilitate the installation.
IMPORTANT: Do not bend or twist the float arm.
5. Insert the float and the float arm into the fuel tank opening.
6. Install the float arm retaining clip.
7. Align the fuel sender gasket tab (1) with the fuel sender cover mark (2).
8. Align the fuel sender cover mark (2) with the fuel tank mark.
9. Tighten the fuel sender attaching bolts until the bolts are finger tight.
10. Tighten the fuel sender assembly attaching bolts in proper sequence.
Tighten
Tighten bolts to 7 N.m (62 lb in).
11. Connect the fuel sender fuel feed pipe (1) from the jet pump to the left tank, to the fuel return rear pipe (2), and to the fuel feed rear pipe (3).
12. Connect the fuel sender electrical connector.
13. Install the fuel tank strap (3).
14. Install the fuel tank strap bolts (1, 2, 4).
Tighten
- Tighten the bolt (2) to 25 N.m (18 lb ft).
- Tighten the bolt (1) to 25 N.m (18 lb ft).
- Tighten the remaining bolts (4) to 25 N.m (18 lb ft).
15. Install the fuel tank shield (1).
16. Install the fuel tank shield mount bolt (2).
17. Install the fuel tank shield mount nut (3).
Tighten
- Tighten the fuel tank shield mount bolt to 25 N.m (18 lb ft).
- Tighten the fuel tank shield mount nut to 12 N.m (106 lb in).
18. Install the rear wheel and tire assembly.
19. Lower the vehicle.
20. Refill the fuel system.
21. Install the fuel filler cap.
22. Connect the negative battery cable.
23. Perform the following procedure in order to inspect for leaks:
23.1. Turn the ignition switch ON for 2 seconds.
23.2. Turn the ignition switch OFF for 10 seconds.
23.3. Turn the ignition switch ON.
23.4. Inspect for fuel leaks.
24. Program the transmitters. Refer to Transmitter Programming in Keyless Entry.