Fuel Sender Assembly Replacement RH

Tools Required

J39765-A Fuel Sender Lock Ring Tool

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the right fuel tank. Refer to Fuel Tank Replacement .
3. Place the fuel tank on a suitable work surface.



4. Disconnect the evaporative emission (EVAP) purge line (4) from the fuel pump module.
5. Disconnect the fuel pump module harness connector (5).
6. Disconnect the fuel tank pressure (FTP) sensor harness connector (1).
7. If replacing the fuel pump module, remove the FTP sensor (2). Refer to Fuel Tank Pressure Sensor Replacement .
8. Disconnect the jet line insert connector from the crossover tube to fuel tank opening.

Important: The fuel pump module is spring loaded and will spring upward when the locking ring is removed.

9. Using the J39765-A , remove the fuel pump module locking ring.



10. Carefully remove the fuel pump module from the fuel tank, with the jet lines connected. Take care not to damage the fuel sender float arm.
11. Disconnect the jet line quick-connect connectors from the fuel pump module, noting the location of the lines for installation.
12. Remove the fuel pump module O-ring from the fuel tank opening.
13. Remove the jet line insert through the crossover tube to fuel tank opening.

1. Inspect the jet line insert for damage and replace if necessary.
2. Install the jet line insert through the crossover tube to fuel tank opening.



3. Install a new fuel pump module O-ring to the fuel tank opening.

Important: Pull on each connector to ensure that the connectors are properly latched.

4. Pull the jet line quick-connectors up through the pump module opening, connecting the lines to the pump module as previously noted.
5. Install the pump module into the fuel tank, taking care not to damage the float arm.
6. Compress and align the fuel pump module, while installing the lock ring.
7. Using the J39765-A , fully lock the fuel pump module lock ring in place.
8. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading.

Resistance

•	Empty 40 ohms resistance

•	Full 250 ohms resistance

Important: Pull the jet line insert connector to ensure that the insert is properly attached.

9. Connect the jet line insert connector into the crossover tube to fuel tank opening.



10. If replacing the fuel pump module, install the FTP sensor (2). Refer to Fuel Tank Pressure Sensor Replacement .
11. Connect the FTP sensor harness connector (1).
12. Connect the fuel pump module harness connector (5).
13. Connect the EVAP purge line (4) from the fuel pump module.
14. Install the right fuel tank. Refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement LH

Tools Required

J39765-A Fuel Sender Lock Ring Tool

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the left fuel tank. Refer to Fuel Tank Replacement .
3. Place the fuel tank on a suitable work surface.



4. Disconnect the fuel pump jumper harness from the fuel pump module.
5. Disconnect the jet line insert connector from the crossover tube to fuel tank opening.
6. Disconnect the fuel feed line from the welded clip on the side of the fuel tank.

Important: The fuel pump module is spring loaded and will spring upward when the locking ring is removed.

7. Using the J39765-A , remove the fuel pump module locking ring.



8. Carefully remove the fuel pump module from the fuel tank, with the jet lines connected. Take care not to damage the fuel sender float arm.
9. Disconnect the jet line quick-connect connectors from the fuel pump module inner port.
10. Remove the jet line from the module retainer cup. This line has no attached connector.
11. Remove the fuel pump module O-ring from the fuel tank opening.
12. Remove the jet line insert through the crossover tube to fuel tank opening.

1. Inspect the jet line insert for damage and replace if necessary.
2. Install the jet line insert through the crossover tube to fuel tank opening.
3. Install a new fuel pump module O-ring to the fuel tank opening.
4. Place tape around the jet line with the connector. This will permit line access once the pump module is inserted into the fuel tank.



5. Install the pump module into the fuel tank half way , taking care not to damage the float arm.
6. Using the tape as a guide, gently pull the jet line up through the fuel pump module opening.
7. Place the jet line with no connector in the module retainer cup.
8. Secure the line into the module retaining clip.
9. Remove the tape from the jet line with a connector.

Important: Pull on each connector to ensure that the connectors are properly latched.

10. Connect the jet line quick-connect connectors to the fuel pump module inner port.
11. Compress and align the fuel pump module into the fuel tank, while taking care not to damage the float arm.
12. Install the fuel pump module lock ring.
13. Using the J39765-A , fully lock the fuel pump module lock ring in place.
14. Connect the fuel supply line into the weld clip on the side of the fuel tank.
15. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading.

Resistance

•	Empty tank reading 40 ohms resistance

•	Full tank reading 250 ohms resistance

Important: Pull the jet line insert connector to ensure that the insert is properly attached.

16. Connect the jet line insert connector into the crossover tube to fuel tank opening.



17. Connect the fuel pump jumper harness to the fuel pump module.
18. Install the left fuel tank. Refer to Fuel Tank Replacement .