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.

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.

Important: Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.

Important: The modular fuel sender assembly springs upward when the snap ring is removed.

Important: When removing the modular fuel sender assembly from the fuel tank, the reservoir bowl on the fuel sender assembly is full of fuel. The modular fuel sender assembly must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the modular fuel sender assembly is removed from the fuel tank.

Important: Always maintain cleanliness when servicing fuel system components.

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

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.

2. Disconnect the negative battery cable.
3. Remove the spare tire cover, the jack, and the spare tire.
4. Remove the trunk liner.
5. Remove the nuts (7) retaining the fuel sender access panel.
6. Remove the fuel sender access panel.



7. Disconnect the electrical connector from the fuel tank pressure sensor (7).
8. Clean the fuel pipes and the fuel sender assembly in order to prevent possible fuel contamination during removal.
9. Disconnect the quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .



10. Remove the retaining snap ring from the fuel sender.
11. Remove the modular fuel sender assembly.
12. Clean the O-ring sealing surfaces on the fuel sender assembly.
13. Inspect the 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.

Important: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly as this restricts fuel flow. Also, ensure that the fuel pump strainer does not block full travel of the float arm.

Important: Ensure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.

1. Position the new O-ring on the fuel tank.
2. Reinstall the fuel sender assembly into the fuel tank.
3. Reinstall the retaining snap ring to the fuel sender assembly.



4. Connect the electrical connector to the fuel tank pressure sensor (7).
5. Connect the quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
6. Connect the negative battery cable.
7. Tighten the fuel filler cap.
8. Inspect for leaks.

8.1.	Turn the ignition switch on for 2 seconds.

8.2.	Turn the ignition switch off for 10 seconds.

8.3.	Turn the ignition switch to the on.

8.4.	Inspect for fuel leaks.




9. Reinstall the fuel sender access panel.

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.

10. Install the nuts (7) that retain the fuel sender access panel.

Tighten
Tighten the nuts to 10 N·m (88 lb in)

11. Reinstall the trunk liner.
12. Reinstall the spare tire, the jack, and the spare tire cover.