Fuel Tank Unit: Service and Repair

FUEL SENDER ASSEMBLY REPLACEMENT

PRELIMINARY STEPS
^ Relieve fuel system pressure. Refer to Service and Repair / Fuel Pressure Relief Procedure.
^ Remove negative battery cable from battery.
^ Drain fuel tank. Refer to Fuel Tank / Service and Repair / Fuel Tank Draining.

REMOVE OR DISCONNECT
1. Rear seat cushion.

Removing Floor Service Hole Cover:

2. Four screws and floor service hole cover (see image).
3. Fuel sender assembly electrical connector.

Fuel Sender Assembly Hose Connections:

4. One nut and fuel feed hose from fuel sender assembly (see image).
5. One clamp and fuel return hose from fuel sender assembly (see image).

Fuel Sender Assembly Bolts:

6. Eight bolts and fuel sender assembly from fuel tank (see image).

INSTALL OR CONNECT
^ Insert new gasket to fuel sender assembly.
1. Fuel sender assembly to fuel tank; secure with eight bolts. Tighten fuel sender assembly bolts to 4 Nm (35 lb. in.).
2. Fuel return hose to fuel sender assembly; secure with one clamp.
3. Fuel feed hose to fuel sender assembly; secure with one nut. Tighten fuel feed hose-to-fuel sender assembly nut to 30 Nm (22 lb. ft.).
4. Fuel sender assembly electrical connector.
5. Floor service hole cover; secure with four screws.
6. Rear seat cushion.
^ Refill tank.
7. Negative (-) battery cable. Tighten negative (-) battery cable-to-negative (-) battery terminal retainer to 15 Nm (11 lb. ft.).

AFTER REPAIR INSPECTION
Turn ignition switch to "ON" and momentarily connect a jumper between Data Link Connector (DLC) terminals "+B" and "FP" to pressurize the fuel system. Check for any leaks.