Tools Required

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. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Remove the fuel tank. Refer to Fuel Tank Replacement .
5. Disconnect the fuel feed pipe (4), the fuel return pipe (2), and the EVAP pipe (3) from the fuel sender.
6. Disconnect the fuel sender electrical connectors (1) from the fuel sender.



7. Remove the fuel sender assembly retaining ring using the J 39765 Fuel Sender Lock Nut Wrench.




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.

8. Remove the fuel sender assembly.

Caution: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.




9. Remove the fuel sender seal.
10. Discard the fuel sender seal.
11. Clean the seal sealing surfaces.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

Notice: With extreme care align the fuel sender seal in the fuel tank groove. Properly align the tab on the fuel sender in the notch on the fuel tank. Misalignment of the fuel sender seal or the fuel sender could damage the fuel tank sender tabs. Replace the fuel tank if the fuel tank fuel sender tabs are damaged.

1. Install the new fuel sender seal on the fuel tank.




Important: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

2. Install the fuel sender assembly into the fuel tank.



3. Install the fuel sender assembly retaining ring using the J 39765 Fuel Sender Lock Nut Wrench.
4. Perform the fuel tank leak check. Refer to Fuel Tank Leak Check .



5. Connect the fuel sender electrical connectors (1) to the fuel sender.
6. Connect the fuel feed pipe (4), the fuel return pipe (2), and the EVAP pipe (3) to the fuel sender.
7. Install the fuel tank. Refer to Fuel Tank Replacement .
8. Refill the fuel tank.
9. Install the fuel filler cap.
10. Connect the negative battery cable.
11. Inspect for leaks.

11.1.

Turn the ignition switch ON for 2 seconds.

11.2.

Turn the ignition switch OFF for 10 seconds.

11.3.

Turn the ignition switch ON.

11.4.

Check for fuel leaks.

12. Perform the idle learn procedure. Refer to Idle Learn .