Fuel Sender Assembly Service

UPDATED BY TSB # 71-63-04 DATED 8/97

WARNING: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:
- Use forced air ventilation such as a fan set outside of the trunk.
- Plug or cap any fuel system openings in order to reduce fuel vapor formation.
- Clean up any spilled fuel immediately.
- Avoid sparks and any source of ignition.
- Use signs to alert others in the work area that fuel system work is in process.

WARNING: To prevent personal injury, safety goggles must be worn when working with fuel.

Descriptive:

REMOVAL PROCEDURE

Notice: Do Not handle the fuel sender assembly by the fuel pipes. Due to the length of the fuel pipes, the amount of leverage generated by handling the fuel pipes could damage the joints.

1. Relieve the fuel system fuel pressure.
2. Remove the modular fuel sender assembly.
3. Note the position of the fuel sender strainer for the installation.
4. Support the reservoir with one hand and grasp the fuel sender strainer with the other hand.
5. Remove the fuel sender strainer (1).
. Inspect the fuel sender strainer. If the fuel sender strainer is contaminated, the fuel tank should be cleaned.
7. Discard the fuel sender strainer after inspection.
8. Remove the electrical connector from the sensor assembly of the fuel pump and the cover assembly.
9. Remove the fuel level sensor assembly (1).

INSTALLATION PROCEDURE
1. Install the fuel level sensor assembly (1).
2. Install the electrical connectors to the fuel pump and the cover assembly.
3. Install the fuel sender strainer (1).
4. Position the new fuel sender strainer on the modular fuel sender strainer and push on the outer edge of the fuel sender strainer until the fuel sender strainer is fully seated.
5. Install the fuel sender assembly.
6. Add fuel and install the fuel tank filler pipe cap.
7. Install the negative battery cable.
8. Inspect for leaks.
- Inspect turn the ignition switch to the ON position for two seconds.
- Turn the ignition switch to the OFF position for ten seconds.
- Turn the ignition switch back to the ON position.
- Check for fuel leaks.