Fuel Gauge Sender: Service and Repair
FUEL SENDER ASSEMBLY REPLACEMENTTOOLS REQUIRED
J 43827 Fuel Sending Unit Wrench
REMOVAL PROCEDURE
1. Remove the fuel tank.
NOTE: Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.
2. Disconnect the fuel lines from fuel pump module.
NOTE: To prevent retaining ring damage, do not attempt to remove the retaining ring with a 12 inch or shorter ratchet/breaker bar. Operation should be a smooth one-hand operation while holding onto the lock ring.
3. Use the J 43827 remove the fuel pump module retaining ring. A 1/2 in breaker bar, approximately 0.5 m (18 in) will easily loosen and remove the lock ring.
NOTE: To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.
4. Remove the fuel pump module.
IMPORTANT: Always replace the fuel pump module to tank seal O-ring whenever the assembly is removed.
5. Discard the fuel pump module to tank seal.
6. If the sending unit is not being replaced as well, remove the fuel level sender.
INSTALLATION PROCEDURE
1. Install the fuel level sender onto the new fuel pump.
2. Install the new fuel pump with the level sender and the new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
3. Use the J 43827 to install the fuel pump lock ring.
4. Connect the fuel lines and wiring harness.
5. Install the fuel tank.