Passenger/Cargo Van

Fuel Sender Assembly:

REMOVAL PROCEDURE
1. Drain the fuel from the tank. Refer to Draining Fuel Tank.
2. Raise the vehicle.
3. Remove the fuel tank off-road shield, if equipped.
4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.
5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.
6. Lower fuel tank shield.
7. Lower the fuel tank. Disconnect the fuel feed and vapor hoses. Disconnect the electrical connections at the sender.
8. Remove the fuel sender assembly and seal ring, using tool J 39765. Discard the old seal ring. Purge the tank, if the tank is being repaired.

INSTALLATION PROCEDURE
1. Install the new seal ring and reinstall the sender using tool J 39765.
2. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.
3. Raise the tank fully.

NOTE: The fuel tank filler neck clamps must be properly positioned and aligned. Otherwise, the filler neck may become disconnected from the fuel tank.

4. Reinstall the fuel tank filler neck to the tank. Tighten the clamp to 2.75 Nm (24.3 lb in).

NOTE: The strap nuts must be tightened by steps, alternating between the four nuts until the specified torque is reached. Otherwise, the bottom of the tank will flex upward and the fuel gage will indicate fuel remaining in the tank when the tank runs dry.

5. Install the fuel tank brackets with insulator strips in place. Tighten the strap nuts to 45 Nm (33 lb ft).
6. Install the fuel tank off-road shield, if equipped.
7. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
8. Reconnect the negative battery cable. If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
9. Check for leaks.