Tools Required

J 39765 Fuel Sender Locknut Wrench

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Drain the fuel from the tank.

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

3. Raise the vehicle.



4. Loosen the filler neck hose clamp (2) at the fuel tank (1) and disconnect the fuel tank filler neck from the fuel tank.
5. Support the fuel tank.
6. Remove the fuel tank fixing nuts.



7. Disconnect the fuel feed(2) and vapor hoses(3).



8. Disconnect the electrical connector(1) at the sender.
9. Use the J 36608 in order to remove the fuel sender assembly and seal ring. Discard the old seal ring.

1. Install the new seal ring(2) and use the J 36608 in order to reinstall the sender.



2. Raise the tank slightly and reconnect the fuel feed(2) and vapor hoses(3) and the electrical connections(1) at the sender.
3. Raise the tank fully.
4. Install the fuel tank fixing nuts.

Tighten
Tighten the fixing nuts to 45 N·m (33 lb ft).





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.

Important: The fuel tank filler neck clamps must be properly positioned and aligned. Otherwise, the filler neck may become disconnected from the fuel tank.

5. Reinstall the fuel tank filler neck (3) to the tank (1).

Tighten
Tighten the clamp to 2.75 N·m (24.3 lb in).

6. Replenish the fuel in the tank and reinstall the fuel tank filler cap.
7. Reconnect the negative battery cable. Reset all devices that lost memory when the battery was disconnected.
8. Inspect fuel system for leaks.