Tools Required

J 39765 , Fuel Sender Lock Nut WrenchJ 37088-A , Fuel Line Quick-Connect Separator Tool Set

Caution: In order to Reduce the Risk of Personal Injury: Always allow for proper ventilation when working with fuel in enclosed areas.

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

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 the Fuel Pressure Relief .
2. Drain the fuel tank to no more than 1/4 of a tank full. Refer to Fuel Tank Draining .



3. Remove the spare tire cover, ,jack, and the spare tire.
4. Pull back the trunk liner.
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.
7. Remove the quick-connect fittings at the fuel sender assembly. Refer to Servicing Quick Connect Fittings .
8. Remove the electrical connector at the fuel sender.

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.

9. Remove the fuel sender retaining ring using the J 39675 Fuel Sender Spanner Wrench.



10. Remove the fuel sender assembly retaining cam, using the J 39675 Fuel Sender Spanner 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 the fuel sender assembly O-ring sealing surfaces.
14. Inspect the fuel sender assembly O-ring sealing surfaces.

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.

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

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

2. Assemble the fuel sender assembly and the fuel sender assembly retainer cam using the J 39675 Fuel Sender Spanner Wrench.




Important: Care should be taken not to fold over or twist the fuel pump strainer (1) when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

3. Install the fuel sender assembly and the fuel sender assembly retainer cam using the J 39765 Fuel Sender Spanner Wrench.
4. Install the quick-connect fittings at the fuel sender assembly. Refer to Servicing Quick Connect Fittings .
5. Install the negative battery cable.
6. Inspect for leaks.

6.1.	Turn the ignition switch to the On position for 2 seconds.

6.2.	Turn the ignition switch to the Off for 10 seconds.

6.3.	Turn the ignition switch to the On position.

6.4.	Check for fuel leaks.




7. Install the fuel sender access panel.
8. Reposition the trunk liner.
9. Install the spare tire, the jack, and the spare tire cover.



10. Add fuel and install the fuel tank filler pipe cap.