Instruments - Fuel Gauge Sender Unit Replacement
89AMCJEEP012E430
OCTOBER 1987
1988 MEDALLION
ENGINE Attention: Workshop, Parts Department
FUEL GAUGE SENDER UNIT REPLACEMENT
A production change in the 1988 Medallion has altered the fuel gauge sender unit replacement procedures. The fuel tank must now be removed to access the fuel gauge sender unit.
The following procedure supersedes the procedure published in the M.R. 289 service manual.
PROCEDURE
Fuel Tank Removal
1. Disconnect the battery negative cable.
2. Remove any fuel in the tank with a portabletype gasoline storage tank.
3. Raise the vehicle.
4. Remove the passenger side rear tire and wheel.
5. Disconnect ground wire (A) from fuel filler neck (B).
6. Remove hose champs (C) and disconnect filler neck hose (D) from tank (E).
7. Support the tank with a jack or a stand.
8. Remove splash shield (F) and disconnect vent hoses (G) from hose connector (H).
9. Remove the bolts attaching tank retaining straps (J) to the side sill.
10. Lower the fuel tank enough for access to the rollover valve and the fuel gauge sender unit. Disconnect the rollover valve hose and the fuel gauge sender unit wire and hose.
11. Remove the supports and remove the tank from the vehicle.
Fuel Gauge Sender Unit Removal
1. Remove fuel gauge sender unit clamp ring
(K) by tapping the ring in a counterclockwise direction to unscrew it. Use a brass, wood or plastic drift to avoid sparks.
2. Remove the fuel gauge sender unit.
Fuel Gauge Sender Unit Installation
NOTE: When installing the fuel gauge sender unit, be sure to use a replacement gasket. Also be sure the gasket is properly aligned and seated before tightening the clamp ring.
1. Install the fuel gauge sender unit.
2. Tighten clamp ring (K). Tap it clockwise until the ring stops against the tabs. Use a brass, wood or plastic drift to avoid sparks.
Fuel Tank Installation
1. Position the fuel tank under the vehicle using a jack or a stand.
2. Connect the vent hose and wire to the tank sender and connect the hose to the rollover valve.
3. Move the tank into position and install tank retaining straps (J).
4. Connect tank vent hoses (G) to hose connector (H).
5. Use hose clamps (C) to connect the fuel filler neck hose (D) to tank (E).
6. Connect ground wire (A) (from the fuel gauge sender unit) to fuel filler neck (B).
NOTE: Be sure the ground wire is securely connected at both the filler neck and fuel gauge sender unit before proceeding.
7. Install splash shield (F) at the forward part of the wheel house opening.
8. Install the rear tire and wheel. Tighten the wheel bolts to 90 N-m (67 ft.lbs.) torque.
9. Lower the vehicle.
10. Pump the fuel in the portable gasoline storage tank back into the fuel tank.
11. Connect the battery negative cable.
PARTS INFORMATION
DESCRIPTION QUANTITY PART NUMBER
GAUGE, Fuel Sender Unit (without 1 7700 780 240
electronic cluster)
GAUGE, Fuel Sender Unit (with 1 7700 780 241
electronic cluster)
SRT INFORMATION
OPERATION
OPERATION DESCRIPTION NUMBER TIME TIC
CO. SENDER UNIT, FUEL 0116 1.6 * *
GAUGE-REPLACEMENT INC. DRAIN, R & R, and REFILL FUEL TANK
* *TIC CONDITION CODE
Sender Unit: Seal Leak 1-941
Improper Ground 8-383
Low Fuel Warning Sensor 8-332
All Other Incidents 8-384
FILING INSTRUCTIONS
Record this I.S. Note on pages B-62 and B-63 of M.R. 289 and file it in the manual.