Removal and Replacement
TOOLS REQUIRED1. J34730-1A Fuel Pressure Gauge
2. J 39765 Fuel Sender Locknut Wrench
REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
IMPORTANT: If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.
4. Disconnect the fuel feed pipe (1) at the in-line fuel filter and return pipe (2) near the in-line fuel filter.
5. Grasp both ends of the fuel feed pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick connect fittings.
CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.
6. Blow out dirt from quick connect fittings using compressed air.
7. Squeeze the plastic tabs of male end connector of fuel filter.
8. Pull connection apart.
9. Repeat steps 5 through 8 for the other fitting.
10. Disconnect the clamps (3) at the fuel filler neck (2) and fuel filler neck vent pipe (1) at the fuel tank (4).
11. Remove the fuel filler neck (2) and fuel filler neck vent pipe (1) from the fuel tank (4).
12. Disconnect the fuel sender (1) electrical connector.
13. Remove the exhaust heat shield screws and reposition shield.
NOTE: Do not bend the fuel tank straps as this may damage the straps.
14. Support the fuel tank and remove the fuel tank retaining strap bolts (2) from the fuel tank retaining strap (3).
15. Lower the fuel tank and disconnect the [1][2]EVAP pipe.
16. Inspect the connectors for dirt and damage. Clean or replace as required.
17. Remove the fuel sender assembly (1) from the fuel tank using J 39765 Fuel Sender Lock nut Wrench.
INSTALLATION PROCEDURE
IMPORTANT: Always install a new lip seal when servicing the modular fuel sender assembly.
1. Lightly lubricate the inside diameter of the lip seal with clean engine oil.
2. Install fuel sender assembly (1) into the fuel tank (4) using J 39765 Fuel Sender Lock nut Wrench.
IMPORTANT: Assure proper location of fuel sender pipes.
3. Install fuel tank retaining straps (3) attaching bolts (2) with the aid of an assistant to the fuel tank (2).
4. Raise the fuel tank and connect [1][2]EVAP pipe.
Tighten
Tighten the fuel tank strap bolts to 42 N.m (31 lb ft).
Refer to the Fastener Notice in Service Precautions.
5. Install exhaust heat shield screws.
6. Connect the fuel sender electrical connector.
7. Install the fuel filler neck (2) and fuel filler neck vent pipe (1) at the fuel tank (4).
8. Install the clamps (3) at the fuel filler neck (2) and fuel filler neck vent pipe (1).
Tighten
Tighten the clamps to 4.3 N.m (38 lb in).
CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings in order to reduce the risk of fire and personal injury.
This will ensure proper reconnection and prevent a possible fuel leak.
During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
9. Apply a few drops of clean engine oil to the male connector pipe ends.
10. Push connectors together to cause the retaining tabs/fingers to snap into place.
11. Pull on both ends of each connection to make sure connection is secure, once installed.
12. Lower the vehicle.
13. Reinstall the fuel filler cap.
14. Add fuel to the fuel tank.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
15. Connect the negative battery cable.
16. Inspect for fuel leaks.
16.1. Turn ignition switch to ON for 2 seconds.
16.2. Turn the ignition switch to OFF for 10 seconds.
16.3. Turn the ignition switch ON.
16.4. Check for fuel leaks.
17. Reinstall the intake manifold sight shield.