Fuel Gauge Sender: Service and Repair

TOOLS REQUIRED
^ J 43827 Lock Ring Remover

REMOVAL

CAUTION: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place.




1. Remove fuel tank.

NOTE: To prevent retaining ring damage, do not attempt to remove retaining ring with a 12 in. or shorter ratchet/breaker bar.

2. Remove fuel lines and electrical connector from fuel pump cover.




3. Use lock ring service tool (J43827) and remove fuel pump module retaining ring. A 1/2 in. breaker bar (approximately 18 inches long) will easily loosen and remove the lock ring.
4. Pull up fuel pump module cover and disconnect the sending unit electrical connector on the bottom side of the fuel pump module cover (be sure to release retaining clip).
5. Remove the sender by depressing locking tab and pulling up. The locking tab is square not round.

IMPORTANT: The fuel pump assembly is only serviced as a module without the sender unit. The inlet filter can be cleaned with mineral spirits; however, it cannot be replaced.

INSTALLATION
1. Slide new sender unit into place until click is heard. (Pulling up lightly to ensure sender unit is locked into place.)

IMPORTANT: Verify that float arm on sender unit maintains correct relationship to pump module by standing module on a flat, horizontal surface. The float should lay on the surface.

To verify function and calibration of sending unit, refer to "Fuel Tank Unit Calibration and Electrical Circuit" procedures.




2. Connect electrical connector.

IMPORTANT: The fuel pump module to tank seal must always be replaced whenever module is removed from fuel tank.

3. Install pump module cover and lock ring using a new tank seal.
4. Reconnect fuel lines and electrical connector to fuel pump cover.
5. Perform "Service Bay Diagnostic Test" for evaporative emission system using Scan tool. This test will verify integrity of vapor handling areas of fuel system.