Removal Procedure
Tools Required
• | J 39765 Fuel
Sender Lock Nut Wrench |
Caution: Provide proper ventilation when working with fuel in enclosed areas
where fuel vapors can collect. The lack of adequate ventilation may result
in personal injury.
Caution: Always wear safety goggles when working with fuel in order to protect
the eyes from fuel splash.
Notice: 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.
- Relieve the fuel system fuel pressure. Refer to the
Fuel Pressure Relief
.
- Drain the fuel tank to at least 3/4 of a tank full. Refer to
Fuel Tank Draining
.
Important: The modular fuel sender support assembly will spring-up when the locking
ring is moved.
- Remove the fuel sender assembly. Refer to
Fuel Sender Assembly Replacement
.
Disassemble Procedure
- Note the position of the
fuel sender strainer for installation (4).
- Support the reservoir with one hand and grasp the fuel sender
strainer with the other hand.
- Pull the fuel sender strainer off of the fuel sender assembly.
- Inspect the fuel sender strainer. If the fuel sender strainer
is contaminated, the fuel tank should be cleaned. Refer to
Fuel System Cleaning
.
- Discard the fuel sender strainer after inspection.
- Disassemble the electrical
connectors from the sensor assembly of the fuel pump and the cover assembly.
- Disassemble the fuel level sensor assembly (5).
Assemble Procedure
- Assemble the fuel level
sensor assembly.
- Assemble the electrical connectors to the fuel pump and the cover
assembly.
- Assemble the rubber pad on the bottom of the modular fuel sender.
- Position the new fuel
sender strainer on the modular fuel sender and push on the outer edge of the
fuel sender strainer until the fuel sender strainer is fully seated.
Installation Procedure
- Install the fuel sender assembly. Refer to
Fuel Sender Assembly Replacement
.
- Install the rear seat cushion. Refer to
Rear Seat Cushion Replacement
.
- Install the spare tire
cover, the jack, and the spare tire.
- Install the rear compartment floor trim. Refer to Compartment
Trim panel Replacement - Rear.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the fuel
sender access panel.
Tighten
Tighten the fuel sender access panel bolts to 2 N·m (18
lb in).
- Add fuel and install the
fuel tank filler pipe cap (1).
- Inspect for leaks.
7.1. | Turn the ignition ON for 2 seconds. |
7.2. | Turn the ignition OFF for 10 seconds. |
7.3. | Turn the ignition ON. |
7.4. | Check for fuel leaks. |