Fuel Tank Unit: Service and Repair

REMOVAL PROCEDURE

CAUTION:
^ Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
^ Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.
^ Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.
^ Remove the rear compartment floor trim to provide technician contact with the vehicle's metal surfaces. Failure to remove the rear compartment floor trim may cause a static electricity discharge to ignite any fuel vapor resulting in personal injury and vehicle damage.
^ 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.

NOTE:
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
^ Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
^ The fuel pipe connections
^ The hose connections
^ The areas surrounding the connections

IMPORTANT:
^ For rear compartment (trunk) accessible fuel sender assemblies, completely remove the rear compartment carpet before removing the fuel sender access panel.
^ Always replace the fuel sender O-ring when reinstalling the fuel sender assembly.
^ The modular fuel sender assembly will spring-up when the snap ring is removed.
^ When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The modular fuel sender assembly must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the modular fuel sender assembly is removed from the fuel tank.
^ Always maintain cleanliness when servicing fuel system components.




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the trunk liner.
3. Remove the (7) nuts retaining the fuel sender access panel.
4. Remove the fuel sender access panel.
5. Disconnect the fuel tank pressure sensor electrical connector.
6. Disconnect the fuel sender electrical connector.
7. Clean the fuel pipes, and fuel sender assembly to prevent possible fuel contamination during removal.
8. Disconnect the quick-connect fittings at the fuel sender assembly.
9. Remove the fuel sender retaining snap ring.




10. Remove the modular fuel sender assembly.
11. Clean the fuel sender assembly O-ring sealing surfaces.
12. Inspect the fuel sender assembly O-ring sealing surfaces.


INSTALLATION PROCEDURE

NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

IMPORTANT:
^ Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.
^ Be sure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.




1. Position the new fuel sender assembly O-ring on the fuel tank.
2. Reinstall the fuel sender assembly into the fuel tank.
3. Reinstall the fuel sender assembly retaining snap ring.
4. Connect the fuel sender electrical connector.
5. Connect the fuel tank pressure sensor electrical connector.
6. Connect the quick-connect fittings at the fuel sender assembly.
7. Reinstall the fuel fill cap.
8. Reconnect the negative battery cable.
9. Inspect for leaks.
9.1. Turn the ignition switch ON for 2 seconds.
9.2. Turn the ignition switch OFF for 10 seconds.
9.3. Turn the ignition switch ON.
9.4. Check for fuel leaks.
10. Reinstall the fuel injection sight shield.




11. Reinstall the fuel sender access panel.

NOTE: Refer to Fastener Notice in Cautions and Notices.

12. Install the (7) nuts retaining the fuel sender access panel.

Tighten
Tighten the fuel sender access panel nuts to 10 N.m (8 lb ft).

13. Reinstall the trunk liner.