Fuel Sender Assembly Service

Removal Procedure

Tools Required




J 34730 Fuel Pressure Gauge

Caution: Refer to Service Precautions

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.

Notice: Clean All Connections in Order to A void Contamination.

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.

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Release Procedure. Fuel Pressure Release




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

Important: The modular fuel sender support assembly will spring-up when the locking ring is moved.




3. Remove the fuel sender assembly.

Disassemble Procedure




1. Note the position of the fuel sender strainer for installation (4).
2. Support the reservoir with one hand and grasp the fuel sender strainer with the other hand.




3. Pull the fuel sender strainer off of the fuel sender assembly.
4. Inspect the fuel sender strainer. If the fuel sender strainer is contaminated, the fuel tank should be cleaned. Refer to Fuel System Cleaning. Service and Repair
5. Discard the fuel sender strainer after inspection.




6. Disassemble the electrical connectors from the sensor assembly of the fuel pump and the cover assembly.
7. Disassemble the fuel level sensor assembly.

Assemble Procedure



1. Assemble the fuel level sensor assembly.
2. Connect the electrical connectors to the fuel pump and the cover assembly.
3. Assemble the rubber pad on the bottom of the modular fuel sender.




4. Position the new fuel sender strainer on the modular fuel sender and push on the outer edge of the fuel sender strainer until the fuel sender strainer is fully seated.

Installation Procedure



1. Reinstall the fuel sender assembly.




2. Add fuel and Reinstall the fuel tank filler pipe cap (1).
3. Connect the negative battery cable.
4. Inspect for fuel leaks.
4.1. Turn the ignition switch ON for 2 seconds.
4.2. Turn the ignition switch OFF for 10 seconds.
4.3. Turn the ignition switch ON.
4.4. Check for fuel leaks.

Notice: Refer to Fastener Notice in Service Precautions.




5. Install the fuel sender access panel.
Tighten the fuel sender access panel bolts to 2 N.m (18 lb in).




6. Reinstall the rear compartment floor trim (1).
7. Reinstall the spare tire cover, the jack, and the spare tire.
8. Reinstall the rear seat cushion.
9. Reinstall the intake manifold sight shield. Refer to Engine Cover Replacement Service and Repair.