Fuel Tank Unit: Service and Repair
FUEL SENDER ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
CAUTION: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:
- Use forced air ventilation such as a fan set outside of the trunk.
- Plug or cap any fuel system openings in order to reduce fuel vapor formation.
- Clean up any spilled fuel immediately.
- Avoid sparks and any source of ignition.
- Use signs to alert others in the work area that fuel system work is in process.
1. Relieve the fuel system pressure. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove the rear compartment trim panel.
4. Remove the fuel sender access panel bolts.
5. Remove the fuel sender access panel.
6. Disconnect the fuel sender quick-connect fittings.
NOTE: In order to prevent damage, cover the fuel pipe fittings with a shop towel before disconnecting the fuel pipes or removal of the fuel sender retaining ring, in order to catch any fuel that may leak out. Place the towel in an approved container when procedure is completed.
7. Disconnect the fuel sender electrical connector.
8. Disconnect the fuel tank pressure sensor electrical connector.
9. Remove the fuel sender retaining ring using the fuel sender lock nut wrench.
IMPORTANT: The modular fuel sender assembly will spring-up when the locking ring is removed.
10. Remove the fuel sender assembly.
NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
IMPORTANT: When removing the fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender is full of fuel. The fuel sender must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the fuel sender is removed from the fuel tank.
11. Clean the fuel sender sealing surfaces.
12. Inspect the fuel sender sealing surfaces.
INSTALLATION PROCEDURE
1. Position the new fuel sender seal on the fuel tank.
IMPORTANT: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of the float arm. Always replace the fuel sender seal when reinstalling the fuel sender.
2. Install the fuel sender assembly and the fuel sender lock ring using the fuel sender lock nut wrench.
3. Connect the quick-connect fittings at the fuel sender.
4. Connect the fuel sender electrical connector.
5. Connect the fuel tank pressure sensor electrical connector.
6. Add fuel to the fuel tank.
7. Install the fuel tank filler pipe cap.
8. Connect the negative battery cable.
9. Perform the following procedure in order to inspect for leaks:
9.1. Turn ON the ignition, with the engine OFF for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn ON the ignition, with the engine OFF.
9.4. Inspect for fuel leaks.
10. Install the fuel sender access panel.
11. Install the fuel sender access panel bolts.
NOTE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
Tighten the fuel sender access panel bolts to 2 N.m (18 lb in).
12. Install the rear compartment trim panel.
13. Install the fuel injector sight shield.