Tools Required

J 39765 Fuel Sender Locknut 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 trim panel. Refer to Rear Compartment Side Trim Replacement - Right Side in Body Rear End.
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 .

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: 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 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 .
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. Perform the following procedure in order to inspect for leaks:

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

9.2.	Turn OFF the ignition for 10 seconds.

9.3.	Turn ON the ignition, with the engine OFF.

9.4.	Inspect for fuel leaks.




10. Install the fuel sender access panel.

Notice: Refer to Fastener Notice in the Preface section.

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 trim panel. Refer to Rear Compartment Side Trim Replacement - Right Side in Body Rear End.
13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.