Fuel Sender Assembly Replacement
Fuel Sender Assembly
Tool Required - J 39765 Fuel Sender Locknut Wrench
Notice: Do Not handle the fuel sender assembly by the fuel pipes. Due to the length of the fuel pipes, the amount of leverage generated by handling the fuel pipes could damage the joints.
Important: Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.
1.Remove negative battery cable.
2.Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Release.
3.Drain the fuel tank to no more than 1/4 of a tank full.
4.Remove the spare tire cover, the jack, and the spare tire.
5.Pull back the trunk liner.
6.Remove the fuel sender access panel. See illustration.
7.Remove the quick-connect fittings at the fuel sender assembly.
8.Remove the electrical connector at the fuel sender.
9.Remove the fuel sender retaining ring using the J 39765 Fuel Sender Spanner Wrench. Important: When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The modular fuel sender assembly must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the modular fuel sender assembly is removed from the fuel tank. The modular fuel sender assembly will spring-up when the locking ring is removed.
10.Pull the modular fuel sender straight up while pumping the fuel from the reservoir.
11.Clean the fuel sender assembly O-ring sealing surfaces.
12.Inspect the fuel sender assembly O-ring sealing surfaces.
1.Position the new fuel sender assembly O-ring 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 float arm.
2.Install the fuel sender assembly and the fuel sender assembly retainer cam using the J 39765 Fuel Sender Spanner Wrench.
3.Install the quick-connect fittings at the fuel sender assembly.
4.Install the negative battery cable.
5.Inspect for leaks.
5.1. Turn the ignition switch to the On position for 2 seconds.
5.2. Turn the igniti6n switch to the Off for 10 seconds.
5.3. Turn the ignition switch to the On position.
5.4. Check for fuel leaks.
6.Install the fuel sender access panel.
7.Reposition the trunk liner.
8.Install the spare tire, the jack, and the spare tire cover.
9.Add fuel and install the fuel tank filler pipe cap.
Monday, June 21st, 2010 AT 7:32 PM