Tools Required

J 43827 Fuel Sending Unit Wrench

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Remove the fuel lines and electrical connectors from the fuel pump cover.




Notice: To prevent retaining ring damage, do not attempt to remove the retaining ring with a 12 inch or shorter ratchet/breaker bar. Operation should be a smooth one-hand operation while holding onto the lock ring.

3. Use the J 43827 remove the fuel pump module retaining ring. A 1.3 cm (1/2 in) breaker bar, approximately 46 cm (18 in) long, will easily loosen and remove the lock ring.

Notice: To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.

Important: The fuel pump assembly is only serviced as a module without the sender unit. The inlet filter can be cleaned with mineral spirits, however, it can not be replaced.

4. Remove the fuel pump from the fuel tank.



5. Remove the wires from the clip.



6. Remove the positive and negative connectors from the top of the pump.



7. Remove the connector housing from the bottom side of the fuel pump cover. Disengage the locking tab with a fingernail or a small flat blade screwdriver.



8. Remove the fuel level sender card by depressing the locking tab and sliding the card up, toward the fuel pump cover.

1. Slide the new sender unit into place until a click is heard, pulling up lightly to ensure the sender unit is locked into place.

Important: Verify that the float arm on the sender unit maintains the correct relationship to the pump module by standing the module on a flat, horizontal surface. The float should lay on the surface.

2. Connect the electrical connections.

Important: The fuel pump module to tank seal must always be replaced whenever the module is removed from the fuel tank.

3. Install the pump module and lock ring using a new tank seal.
4. Reconnect the fuel lines and electrical connectors to the fuel pump.
5. Install the fuel tank. Refer to Fuel Tank Replacement .