Fuel Sender Assembly Replacement RPO NT7

Tools Required

J 45722 Fuel Sender Lock Ring Wrench

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the rear compartment liner. Refer to Rear Compartment Trim Panel Replacement .
3. Remove the fuel sender access hole cover bolts.
4. Remove the fuel sender access hole cover.



5. Disconnect the fuel feed rear pipe quick connect fitting (3) from the sender. Refer to Plastic Collar Quick Connect Fitting Service .
6. Disconnect the fuel level sensor wiring harness electrical connectors (1, 2) from the pressure sensor and sender.
7. Reposition the fuel feed pipe and harness connectors out of the way.



8. Install the J 45722 to the lock ring.




Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

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: 

•	The fuel sender assembly may spring up from its position.

•	When removing the fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard the fuel sender assembly O-ring seal and replace it with a new one.

•	Carefully discard the fuel in the reservoir bucket into an approved container.

Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

9. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Rotate the lock ring in a counterclockwise direction.



10. Remove the J 45722 and the fuel sender lock ring.
11. Slowly raise the sender until the fuel level sensor float arm is just visible.

Important: When removing the sender from the fuel tank, be aware that the sender reservoir bucket is full of fuel. The sender must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

12. Tilt the sender toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the sender from the tank.
13. Carefully discard the fuel in the sender reservoir bucket into an approved fuel container.

Important: DO NOT reuse the old fuel pump sender seal.

14. Remove and discard the fuel pump sender O-ring seal.




Important: 

•	Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.

•	Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

•	Check the lock ring for flatness.

15. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 different points.
16. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
17. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Place a NEW fuel pump sender O-ring seal onto the fuel tank.

Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.

2. Tilt the sender toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the sender into the fuel tank.
3. Lower the sender assembly into the tank.
4. Install the sender lock ring, and move it into position on the top of the sender.



5. Install the J 45722 to the lock ring.




Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.

Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
6. Using the J 45722 and a breaker bar, rotate the fuel sender lock ring clockwise until the ring is locked into place on the fuel tank.
7. Remove the J 45722 .



8. Position the fuel feed pipe and harness connectors.
9. Connect the fuel level sensor wiring harness electrical connectors (1, 2) to the pressure sensor and sender.
10. Connect the fuel feed rear pipe quick connect fitting (3) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
12. Perform the following procedure in order to inspect for leaks:

12.1.

Turn ON the ignition, with the engine OFF for 2 seconds.

12.2.

Turn OFF the ignition for 10 seconds.

12.3.

Turn ON the ignition, with the engine OFF.

12.4.

Inspect for fuel leaks.




13. Install the fuel sender access hole cover.

Notice: Refer to Fastener Notice in the Preface section.

14. Install the fuel sender access hole cover bolts.

Tighten
Tighten the bolts to 2 N·m (18 lb in).

15. Install the rear compartment liner. Refer to Rear Compartment Trim Panel Replacement .
16. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .

Fuel Sender Assembly Replacement RPO NU6

Tools Required

J 45722 Fuel Sender Lock Ring Wrench

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the rear compartment liner. Refer to Rear Compartment Trim Panel Replacement .
3. Remove the fuel sender access hole cover bolts.
4. Remove the fuel sender access hole cover.



5. Disconnect the fuel feed rear pipe quick connect fitting (3) from the sender. Refer to Plastic Collar Quick Connect Fitting Service .
6. Disconnect the evaporative emission (EVAP) pipe quick connect fitting (1) from the sender. Refer to Plastic Collar Quick Connect Fitting Service .
7. Disconnect the fuel level sensor wiring harness electrical connectors (4) from the sender.
8. Reposition the fuel feed pipe, EVAP pipe, and harness connector out of the way.



9. Install the J 45722 to the lock ring.




Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

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: 

•	The fuel sender assembly may spring up from its position.

•	When removing the fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard the fuel sender assembly O-ring seal and replace it with a new one.

•	Carefully discard the fuel in the reservoir bucket into an approved container.

Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

10. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Rotate the lock ring in a counterclockwise direction.
11. Remove the J 45722 .



12. Raise the sender slightly from the fuel tank and disconnect the vent line quick connect fitting (1) from the sender. Refer to Plastic Collar Quick Connect Fitting Service .
13. Remove the fuel sender lock ring.



14. Slowly raise the module until the vapor line quick connect fittings (1) are visible.
15. In order to prevent the internal vent lines from dropping into the raw gasoline, tie a string to the lines and secure.
16. Disconnect the vapor line quick connect fittings (1 and 2) from the module flange. Refer to Plastic Collar Quick Connect Fitting Service .



17. Slowly raise the sender until the fuel level sensor float arm is just visible.

Important: When removing the sender from the fuel tank, be aware that the sender reservoir bucket is full of fuel. The sender must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

18. Tilt the sender toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the sender from the tank.
19. Carefully discard the fuel in the sender reservoir bucket into an approved fuel container.

Important: DO NOT reuse the old fuel pump sender seal.

20. Remove and discard the fuel pump sender O-ring seal.




Important: 

•	Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.

•	Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

•	Check the lock ring for flatness.

21. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 different points.
22. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
23. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Place a NEW fuel pump sender O-ring seal onto the fuel tank.

Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.

2. Tilt the sender toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the sender into the fuel tank.
3. Lower the sender assembly into the tank.



4. Connect the internal vent line quick connect fittings (1 and 2) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .
5. Remove the string securing the internal vent lines.
6. Install the sender lock ring, and move it into position on the top of the sender.



7. Connect the vent line quick connect fitting (1) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .



8. Install the J 45722 to the lock ring.




Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.

Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
9. Using the J 45722 and a breaker bar, rotate the fuel sender lock ring clockwise until the ring is locked into place on the fuel tank.
10. Remove the J 45722 .



11. Position the fuel feed pipe and harness connector.
12. Connect the EVAP line quick connect fitting (1) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .
13. Connect the fuel feed rear pipe quick connect fitting (3) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .
14. Connect the fuel level sensor wiring harness electrical connector (4) to the sender.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Perform the following procedure in order to inspect for leaks:

16.1.

Turn ON the ignition, with the engine OFF for 2 seconds.

16.2.

Turn OFF the ignition for 10 seconds.

16.3.

Turn ON the ignition, with the engine OFF.

16.4.

Inspect for fuel leaks.




17. Install the fuel sender access hole cover.

Notice: Refer to Fastener Notice in the Preface section.

18. Install the fuel sender access hole cover bolts.

Tighten
Tighten the bolts to 2 N·m (18 lb in).

19. Install the rear compartment liner. Refer to Rear Compartment Trim Panel Replacement .
20. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .