Fuel Gauge Sender: Service and Repair

Fuel Tank Mounting:

Fuel Tank Insulators:

WARNING: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

NOTE: If nylon fuel feed or return lines become kinked, and cannot be straightened, they must be replaced.

REMOVAL:

1. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
2. Drain the fuel tank, refer to MAINTENANCE PROCEDURES/DRAINING THE FUEL TANK.
3. Raise the vehicle on a hoist.
4. Remove the filler tube and clamp.
5. Remove the fuel tank vent tube and clamp at the fuel tank.
6. Disconnect the electrical connector.
7. Remove the vapor connecting hose and clamp from the fuel tank.
8. Grasp the fuel level meter fuel feed tube and fuel feed line quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within the quick-connect fitting. Repeat for the fuel return line quick-connect fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

^ Using compressed air, blow out dirt from the quick-connect fittings.
9. Disconnect the quick-connect fittings:
^ Squeeze the plastic tabs of the male end connector and pull the connection apart. Repeat for the other fitting.

CAUTION: DO NOT bend the fuel tank retaining straps, as this may damage the straps.

10. With the aid of an assistant, support the fuel tank and remove the front fuel tank retaining strap attaching bolts, rear fuel tank strap attaching nuts and bolts, both fuel tank retaining straps and fuel tank.
^ Place the fuel tank in a suitable work area.
11. If it is necessary to remove rust or burrs from the fuel level meter fuel tubes: Use emery cloth in a radial motion with the tube end to prevent damage to O-ring sealing surface.
^ Using a clean shop towel, wipe off the male tube ends.
^ Inspect all connectors for rust or burrs. Clean or replace components/assemblies as required.
^ Check fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.
12. Remove the fuel level meter assembly retaining cam, using J 24187/J 24187-A or available tool J 36608. Remove the fuel level meter assembly and O-ring from the fuel tank. Discard the O-ring.
13. Remove the insulator pads from the fuel tank and spacers from the front fuel tank strap mounting brackets if damaged or a new fuel tank is to be installed. Note the location of the pads for installation.
14. Clean the fuel level meter assembly O-ring sealing surfaces.

INSTALLATION:

1. Position a new fuel level meter assembly O-ring on the fuel tank.
^ Care should be taken not to fold over or twist the fuel pump filter (strainer) when installing the fuel level meter assembly, as this will restrict the fuel flow. Also, assure that the fuel pump filter does not block the full travel of the float arm.
2. Install the fuel level meter assembly and the fuel level meter assembly retainer cam using J 24187/J 24187-A or available tool J 36608.
3. Install insulator pads on the fuel tank and spacers on the front fuel tank strap mounting brackets in the same location as noted during disassembly.
4. With the aid of an assistant, position and support the fuel tank. Install the fuel tank retaining straps, front attaching bolts and the rear bolts and nuts.
^ Tighten the front retaining strap bolts to 34 Nm (25 lb.ft).
^ Tighten the rear retaining strap nuts to 11 Nm (97 lb.in).

WARNING: To reduce the risk of fire and personal injury: Before connecting the fuel line fittings, always drop a few drops of clean engine oil to the male tube ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated).

5. Connect the fuel feed and return line quick-connect fitting to the fuel level meter:
a. Apply a few drops of clean engine oil to the male tube ends.
b. Push the connectors together to cause the retaining tabs/fingers to snap into place.
c. Once installed, pull both ends of each connection to make sure connection is secure.
d. Repeat for the other fitting.
6. Install the vapor connecting hose and clamp.
7. Connect the fuel level meter electrical connector.
8. Install the fuel tank vent tube and clamp.
9. Install the filler tube and clamp.
10. Lower the vehicle.
11. Add fuel and install the fuel filler cap.
12. Connect the negative battery cable.
13. Turn the ignition switch to the ON position for two seconds, then turn it to the OFF position for ten seconds. Again turn the ignition switch to the ON position and check for fuel leaks.