Tools Required

J 39765 Fuel Sender Lock Nut Wrench

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:

1. Relieve the fuel system pressure. Refer to Plastic Collar Quick Connect Fitting Service .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the rear compartment floor trim.
4. Remove the fuel sender access panel bolts.
5. Remove the fuel sender access panel.




Notice: 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 Plastic Collar Quick Connect Fitting Service .
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 using the J 39765 fuel sender lock nut wrench.

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.

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.

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.

Important: 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 Plastic Collar Quick Connect Fitting Service .
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. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
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.

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.




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. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-3.8L.