Fuel Gauge Sender: Service and Repair

Fuel Tank Mounting:

Fuel Tank Insulators:

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Service and Repair
3. Drain the fuel tank.
4. Raise the vehicle.

CAUTION: If nylon fuel feed and return lines become kinked, they cannot be straightened and must be replaced. DO NOT attempt to repair sections of fuel lines. If damaged, replace.

5. Disconnect the fuel feed and return line quick-connect fittings at the fuel level meter.
a. Grasp both ends of one fuel line connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connect fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

b. Using compressed air, blow the dirt out of the quick-connect fittings. Squeeze the plastic tabs of the male end connector of the fuel filter, then pull the connection apart.
c. Repeat for the fuel return line fitting.
6. Wipe the vapor hose connection, release and move the vapor hose clamp, and then disconnect.
7. Disconnect the fuel level meter electrical connector.

CAUTION: DO NOT bend the fuel tank retaining straps, as this may damage the straps.

8. With the aid of an assistant, support the fuel tank and remove the front fuel tank strap attaching bolts, rear fuel tank strap attaching nuts and bolts, both retaining straps and fuel tank.
^ Place the fuel tank in a suitable work place.

FUEL LEVEL METER/PUMP ASSEMBLY

Fuel Pump/Sending Unit Installation (Convertible):

CLEANING AND INSPECTION:
^ Using a clean shop towel, wipe off the male tube end.
^ Inspect all connectors for dirt and damage. Clean or replace components/assemblies as required.
^ Always replace the fuel level meter O-ring when reinstalling the fuel level meter assembly.

REMOVAL:

Tool required: J 24187 Fuel Tank Sending Unit Spanner Wrench.

1. Using the J 24187 remove the fuel level meter assembly retaining cam, fuel level meter assembly and O-ring from the fuel tank. Discard the O-ring.

INSTALLATION:

NOTE: Care should be taken not to fold over or twist the fuel pump filter when installing the fuel level meter assembly as this will restrict fuel flow. Also, assure that the fuel pump filter does not block the full travel of the float arm. Position the filter as shown in the images.

1. Install a new O-ring on the fuel tank.
2. Install the fuel level meter assembly and fuel level meter assembly retainer cam using tool J 24187.

FUEL TANK INSTALLATION:

NOTE: Assure the proper location of the fuel level meter tubes and rubber line isolator.

1. With the aid of an assistant, position and support the fuel tank. Install the fuel tank retaining straps, front attaching bolts and rear attaching bolts and nuts.
^ Tighten the front fuel tank retaining strap bolts to 34 Nm (26 lb.ft).
^ Tighten the rear retaining strap nuts to 34 Nm (26 lb.ft).
2. Connect the vapor hose clamp.
3. Connect the fuel level meter electrical connector.

WARNING: To reduce the risk of fire and personal injury:
^ Before connecting the fuel line fittings, always apply a few drops of clean engine oil to the male tube ends. This will ensure proper reconnection and prevent possible fuel leaks. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

4. Connect the fuel feed and return line quick-connect fittings.
a. Apply a few drops of clean engine oil to the male tube ends.
b. Push the connectors together to cause the retaining tabs/fingers to snap into place.
c. Once installed, pull on both ends of each connection to make sure the connections are secure.
5. Lower the car.
6. Add fuel and install the fuel filler cap.
7. Connect the negative battery cable.
8. Turn the ignition switch ON for two seconds, then turn it OFF for five seconds. Again turn the ignition switch ON and check for fuel leaks.