Fuel Sender Assembly Replacement FWD

Tools Required

CH-47717 Fuel Lock Ring Remover Tool

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Caution: Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.

Caution: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

Caution: Remove the rear compartment floor trim to provide technician contact with the vehicle's metal surfaces. Failure to remove the rear compartment floor trim may cause a static electricity discharge to ignite any fuel vapor resulting in personal injury and vehicle damage.

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:

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:

Important: 

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .



2. Remove the 2 fasteners (2) of the right side cushion (1) and swing the rear seat bottom cushion (1) up and out of the way.
3. Remove the sill plate from the right side door opening.
4. Fold back the carpet in order to maintain metal-to-metal contact while servicing the fuel sender assembly.



5. Remove the 4 fasteners of the access panel (1) for the fuel sender assembly from the rear seat floor (3).
6. Lift the access panel (1) and disconnect the fuel sender electrical connector (2) from the fuel sender assembly.



7. Remove the retaining clip (1) from the fuel line fitting (2).



8. Disconnect the fuel line (1) from the fuel sender assembly.



9. Unlock the quick connect fitting on-board refueling vapor recovery (ORVR) vent line (1). Refer to Plastic Collar Quick Connect Fitting Service .



10. Disconnect the ORVR vent line (2) from the fuel sender assembly (1).



11. Use the CH-47717 fuel lock ring remover tool (1) in order to loosen the fuel sender assembly lock ring.
12. Clean the area around the fuel and vent lines and the fuel sender assembly in order to prevent possible fuel contamination during removal.



13. Remove the lock ring (1).

Important: Do not spill residual fuel or damage the fuel level sensor float while rotating and tilting the sender assembly during removal.

14. Remove the fuel sender assembly (2) from the fuel tank.

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

1. Install a new O-ring seal (1) onto the fuel tank.



2. Install the fuel sender assembly (2) into the fuel tank through the floor panel opening (3).



3. Align the notch (1) on the fuel sender assembly with the slot (2) in the fuel tank opening.



4. Align the extra ridge (1) on the fuel tank lock ring with the mark (2) on the fuel tank.
5. Gently push down on the fuel sender while rotating the lock ring onto the fuel tank.



6. Use the CH-47717 fuel tank lock ring tool (1) in order to tighten the fuel sender assembly lock ring.



7. After 2 full rotations of the lock ring, watch for the alignment of the lock ring extra ridge (1) with the 2 triangle marks (2) on the fuel tank.
8. Rotate the lock ring until the ridge (1) is positioned within the 16 degree area (3) between the 2 marks (2).



9. Connect the ORVR vent line (2) to the fuel sender assembly (1).



10. Slide the quick connect clasp (1) into the lock position on the ORVR vent line (2).



11. Connect the fuel supply line (1) to the fuel sender assembly.



12. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).



13. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
14. Add fuel to the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

15. Connect the negative battery cable.

Tighten
Tighten the retainer for the negative battery cable terminal to 15 N·m (11 lb ft).

16. Pressurize the fuel system and check for leaks.
17. Install the access panel (1) to the rear seat floor panel (3).
18. Secure the access panel to the body with 4 bolts.

Tighten
Tighten the 4 bolts to 6 N·m (53 lb in).

19. Relocate the carpet under the ride side seat area and the right sill plate area.
20. Install the sill plate to the right side door opening .



21. Lower the rear seat bottom cushion (1) and secure with 2 bolts (2).

Tighten
Tighten the 2 bolts to 41 N·m (30 lb ft).

Fuel Sender Assembly Replacement AWD

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Caution: Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.

Caution: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

Caution: Remove the rear compartment floor trim to provide technician contact with the vehicle's metal surfaces. Failure to remove the rear compartment floor trim may cause a static electricity discharge to ignite any fuel vapor resulting in personal injury and vehicle damage.

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:

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:

Important: 

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .



2. Remove the two fasteners (2) and swing the left rear seat bottom cushion (1) up and out of the way.
3. Remove the sill plate from the left side door opening .
4. Fold back the carpet in order to maintain metal-to-metal contact while servicing the fuel sender assembly.



5. Lift the access panel for the fuel sender assembly from the rear seat floor. The panel is held in place by a butyl caulk seal.
6. Disconnect the fuel sender electrical connector (1) from the fuel sender assembly.
7. Remove the 3 fasteners and the protective fuel line cover from the fuel sender assembly.



8. Remove the retaining clip (2) from the fuel line fitting .
9. Remove the fuel line (1) from the fuel sender assembly.



10. Remove the remaining 5 fasteners (1) securing the hold down plate (2) of the fuel sender assembly.
11. Remove the hold down plate (2).
12. Clean the fuel pipe and the fuel sender assembly to prevent possible fuel contamination during removal.
13. Remove the fuel sender assembly (3) from the fuel tank.
14. Inspect and clean O-ring sealing surfaces on the fuel sender assembly .

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

1. Position the new fuel sender assembly O-ring (4) on the fuel sender assembly.
2. Install the fuel sender assembly (3) into the fuel tank.
3. Install the hold down plate (2) for the fuel sender assembly and secure with the 5 fasteners (1).



4. Install the fuel pipe (1) to the fuel sender fitting.
5. Secure the fuel pipe (1) with the retaining clip (2).
6. Install the protective fuel line cover and secure with the 3 fasteners.

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.

7. Tighten all 8 fuel sender assembly fasteners (1).

Tighten
Tighten the bolts to 6 N·m (53 lb in).




8. Connect the fuel sender electrical connector (1) to the fuel sender assembly.
9. Connect the negative battery cable.
10. Pressurize the fuel system and check for leaks.
11. Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
12. Install the access panel to the rear seat floor.
13. Relocate the carpet under the seat and the left sill plate area.
14. Install the sill plate to the left side door opening .



15. Lower the rear seat bottom cushion.
16. Secure the seat cushion (1) with the two fasteners (2).

Tighten the 2 seat cushion fasteners (2).

Tighten
Tighten the bolts to 41 N·m (30 lb ft).