Fuel Tank Unit: Service and Repair

Fuel Sender Assembly Replacement


REMOVAL PROCEDURE
The fuel pump and the fuel level sensor are integral pants of the fuel sender assembly. In order to service the fuel pump or the fuel level sensor, replace the fuel sender assembly.




1. Remove the fuel tank.
2. Disconnect the fuel supply line (2) from the fuel sender assembly.
3. Disconnect the fuel return line (1) from the fuel sender assembly.
4. Disconnect the electrical connector (4) from the fuel sender assembly.




5. Remove the six fuel sender assembly retaining bolts (3).
6. Remove the fuel sender assembly (1).
7. Remove fuel sender assembly gasket (2).

INSTALLATION PROCEDURE




1. Install a new fuel sender assembly gasket (2).
2. Install the fuel sender assembly (1) into the fuel tank.

NOTE: Refer to Fastener Notice in Cautions and Notices.

3. Secure the fuel sender assembly (1) with the six bolts (3).

Tighten
Tighten the fuel sender assembly bolts to 5 N.m (60 lb in).




4. Reconnect the return fuel line (1) to the fuel sender assembly.
5. Reconnect the fuel supply line (2) to the fuel sender assembly.
6. Reconnect the electrical connector (4) to the fuel sender assembly.
7. Install the fuel tank.
8. Inspect for any fuel leaks. Repair as necessary.