Fuel Pump: Service and Repair

FUEL SENDER ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE

CAUTION: Refer to Actions to take when Working With Fuel in Service Precautions.




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 floor trim.
4. Remove the fuel sender access panel bolts.
5. Remove the fuel sender access panel.

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.




6. Disconnect the fuel sender quick-connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
7. Disconnect the fuel sender electrical connector.
8. Disconnect the fuel tank pressure sensor electrical connector.

IMPORTANT: The modular fuel sender assembly will spring-up when the locking ring is removed.

9. Remove the fuel sender retaining ring.

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.

10. Remove the fuel sender assembly.
11. Clean the fuel sender sealing surfaces.
12. Inspect the fuel sender sealing surfaces.

INSTALLATION PROCEDURE

IMPORTANT:
^ DO NOT fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Ensure that the fuel pump strainer does not block the full travel of the float arm.
^ Always replace the fuel sender seal when reinstalling the fuel sender.




1. Position the new fuel sender seal on the fuel tank.
2. Install the fuel sender assembly and the fuel sender lock ring using the J 39765 fuel sender lock nut wrench.
3. Connect the quick-connect fittings at the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
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. Inspect for leaks.
9.1. Turn ON the ignition for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn ON the ignition.
9.4. Inspect for fuel leaks.

NOTE: Refer to Fastener Notice in Service Precautions.




10. Install the fuel sender access panel.
11. Install the fuel sender access panel bolts.

Tighten
Tighten the fuel sender access panel bolts to 2 N.m (18 lb in).

12. Install the rear compartment floor trim.
13. Install the fuel injector sight shield.