Fuel Pump: Service and Repair

Fuel Sender Service:

Fuel Sender Assembly:

CAUTION: To reduce the risk of fire and personal injury that may result from a fuel leak, always replace fuel sender gasket when reinstalling fuel sender assembly.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Relieve fuel system pressure.
- Refer to Fuel System / Service and Repair. Service and Repair
3. Drain fuel tank.
4. Filler door bezel attaching screws and bezel.
5. Lift fuel tank filler pipe housing and disconnect drain hose from nipple.
6. Fuel tank filler pipe housing.

Clean
Clean all fuel connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.

7. Fuel hoses and EVAP hose from fuel sender assembly.
8. Plug or pinch fuel feed and return hoses.
9. Fuel sender electrical connector.
10. Fuel sender assembly attaching screws, fuel sender assembly and gasket. Discard gasket.


Clean
Gasket sealing surfaces.

Inspect
Fuel feed, return and EVAP hoses for cuts, nicks, swelling or distortion. Replace if necessary.

INSTALL OR CONNECT
1. Position new gasket on fuel tank with notch facing forward in right hand corner of fuel tank.
2. Carefully fold strainer to allow it to fit through opening in tank.
- Make sure it unfolds once placed in the tank.
3. Fuel sender assembly into fuel tank.
4. Attaching screws.

Tighten
Screws alternately and evenly to 4.5 Nm (40 lb. in.).

5. Fuel sender electrical connector.
6. Fuel hoses and EVAP hose.

Tighten
Hose clamps to 1.6 Nm (14 lb. in.).

7. Fuel drain hose to nipple on rubber filler pipe housing, and then position housing around fuel tank filler pipe.
8. Filler door bezel with attaching screws.

Tighten
Screws to 2 Nm (18 lb. in.).

9. Add fuel and install fuel filler cap.
10. Negative battery cable.

INSPECT
Turn ignition switch to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position and check for fuel leaks.