Tools Required

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: 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:

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.

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

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.

Notice: Replace the fuel sender O-rings when re-installing the fuel sender in order to avoid damage to the fuel sender assembly.

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



2. Drain the fuel tank (1) to at least 3/4 of full. Refer to Fuel Tank Draining .



3. Remove the spare tire cover, the jack, and the spare tire.

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.

Notice: Remove the rear compartment floor trim to avoid damage from fuel spillage.

4. Remove the rear compartment trim. Refer to Rear Compartment Trim Panel Replacement in Body Rear End.
5. Remove the fuel sender access panel (1).



6. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.

Notice: Remove the rear compartment floor trim to avoid damage from fuel spillage.

7. Remove the quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
8. Disconnect the electrical connector from the fuel sender.
9. Disconnect the electrical connector from the fuel tank pressure sensor.

Important: The modular fuel sender will spring up when the retaining cam is removed.

Important: When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The 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 fuel sender assembly is removed from the tank.

10. Remove the fuel sender retaining cam, using the J 39765 fuel sender locknut wrench.
11. Remove the fuel sender assembly and the O-ring from the fuel tank.
12. Discard the fuel sender assembly O-ring.
13. Clean and inspect the O-ring sealing surfaces of the fuel sender assembly .

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

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

1. Position the new O-ring on the fuel tank.




Important: Care should be taken not to fold over or twist the fuel pump strainer (4) when installing the fuel sender assembly, as this will restrict the fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

2. Install the fuel sender assembly and the retainer cam, using the J 39765 fuel sender locknut wrench.
3. Install the quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .



4. Connect the electrical connector to the fuel tank pressure sensor.
5. Connect the electrical connector to the fuel sender assembly.
6. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
7. Inspect for leaks.

7.1.	Turn ON the ignition switch for 2 seconds.

7.2.	Turn OFF the ignition switch for 10 seconds.

7.3.	Turn ON the ignition switch.

7.4.	Check for fuel leaks.





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.

8. Install the fuel sender access panel.

Tighten
Tighten the bolts to 2 N·m (18 lb in).

9. Install the rear compartment floor trim. Refer to Rear Compartment Trim Panel Replacement in Body Rear End.
10. Install the spare tire, the jack, and the spare tire cover.
11. Add fuel to the fuel tank.
12. Install the fuel filler cap.