Fuel Sender Assembly Service

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 34730 - 1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

CAUTION:
^ Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The Jack 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.

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.

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief Procedure.
2. Drain the fuel tank to at least 3/4 of a tank full. Refer to Fuel Tank Draining Procedure.





IMPORTANT: The modular fuel sender support assembly will spring-up when the locking ring is moved.

3. Remove the fuel sender assembly.





DISASSEMBLE PROCEDURE
1. Note the position of the fuel sender strainer for installation (4).
2. Support the reservoir with one hand and grasp the fuel sender strainer with the other hand.
3. Pull the fuel sender strainer off of the fuel sender assembly.
4. Inspect the fuel sender strainer. If the fuel sender strainer is contaminated, the fuel tank should be cleaned.
5. Discard the fuel sender strainer after inspection.
6. Disassemble the electrical connectors from the sensor assembly of the fuel pump and the cover assembly.
7. Disassemble the fuel level sensor assembly (5).

ASSEMBLE PROCEDURE




1. Assemble the fuel level sensor assembly.
2. Assemble the electrical connectors to the fuel pump and the cover assembly.
3. Assemble the rubber pad on the bottom of the modular fuel sender.




4. Position the new fuel sender strainer on the modular fuel sender and push on the outer edge of the fuel sender strainer until the fuel sender strainer is fully seated.

INSTALLATION PROCEDURE




1. Install the fuel sender assembly.
2. Install the rear seat cushion.




3. Install the spare tire cover, the jack, and the spare tire.
4. Install the rear compartment floor trim.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Install the fuel sender access panel.

Tighten
Tighten the fuel sender access panel bolts to 2 N.m (18 lb in).




6. Add fuel and install the fuel tank filler pipe cap (1).
7. Inspect for leaks.

7.1. Turn the ignition ON for 2 seconds.
7.2. Turn the ignition OFF for 10 seconds.
7.3. Turn the ignition ON.
7.4. Check for fuel leaks.