Fuel Sender Assembly Service

Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors under Powertrain Management / Service Precautions.

1. Remove the negative battery cable.

Caution: Refer to Battery Disconnect Procedures under Powertrain Management / Service Precautions.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Release.

3. Drain the fuel tank. Refer to Fuel Tank.

4. Remove the fuel tank. Refer to Fuel Tank.

5. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.

6. Remove the fuel sending unit seal (lip) from fuel sending unit cover.

Slide the unit seal downward, past the reservoir, and carefully over the float arm assembly.

If you are replacing the fuel feed or the return hose, proceed to step 7.

7. Loosen the clamps and remove the fuel feed or return hose.

8. Before removing the fuel return hose from the reservoir, disconnect the check valve assembly from the reservoir in order to prevent any damage to the reservoir or the check valve.

9. Remove the fuel level sensor screws.

10. Remove the fuel level sensor.

If you are replacing the fuel pump, proceed to step 11.

11. Loosen the clamp and remove fuel feed hose from fuel pump.

12. Remove the fuel pump electrical connectors.

13. Remove the fuel pump damper ring.

14. Remove the fuel pump.

If you are replacing the fuel pump strainer, proceed to step 15.

15. Remove the fuel pump bracket.

16. Remove the fuel pump strainer.

Installation Procedure

Important: Always install a new strainer when you replace the fuel pump.

1. Install the fuel pump strainer.

2. Install the fuel pump bracket.

3. Install the fuel pump.

4. Install the fuel pump damper ring.

5. Install the fuel pump electrical connectors.

6. Install and secure the fuel feed hose to the fuel pump.

7. Install the fuel level sensor and the attaching screws.

8. Install the fuel level sensor electrical connectors.

9. Install the fuel sending unit seal (lip) to the fuel sending unit cover.

10. Install the fuel sender assembly.

11. Install the fuel tank.

12. Lower the vehicle.

13. Refill the fuel tank.

14. Reconnect the negative battery cable.

15. Crank the engine for a few seconds (turn off the engine if the engine starts) and then check for any fuel leaks.