Fuel Pump: 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.
NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
- The fuel pipe connections
- The hose connections
- The areas surrounding the connections
IMPORTANT:
- For rear compartment (trunk) accessible fuel sender assemblies, completely remove the rear compartment carpet before removing the fuel sender access panel.
- Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.
- The modular fuel sender assembly will spring-up when the snap ring is removed.
- Always maintain cleanliness when servicing fuel system components.
1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Release.
2. Remove the rear compartment trim panel.
3. Remove the fuel sender access panel nuts.
4. Remove the fuel sender access panel.
5. Disconnect the fuel tank pressure sensor electrical connector.
6. Disconnect the fuel sender electrical connector.
7. Clean the fuel pipes, and fuel sender assembly to prevent possible fuel contamination during removal.
8. Disconnect the quick-connect fittings at the fuel sender assembly.
9. Remove the fuel sender retaining ring.
10. Remove the modular fuel sender assembly.
11. Clean the fuel sender assembly O-ring sealing surfaces.
12. Inspect the fuel sender assembly O-ring sealing surfaces.
INSTALLATION PROCEDURE
1. Position the new fuel sender assembly O-ring on the fuel tank.
NOTE: Refer to Fuel System Ground Notice in Service Precautions.
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 float arm.
- Ensure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.
2. Install the fuel sender assembly into the fuel tank.
3. Install the fuel sender assembly retaining ring while holding the fuel sender assembly down.
4. Connect the fuel sender electrical connector.
5. Connect the fuel tank pressure sensor electrical connector.
6. Connect the quick-connect fittings at the fuel sender assembly.
7. Install the fuel filler 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.
10. Install the fuel sender access panel.
11. Install the fuel sender access panel nuts.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the nuts to 10 N.m (89 lb in).
12. Install the rear compartment trim panel.