Fuel Tank Unit: Service and Repair

Fuel Sender Assembly Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair
3. Drain the fuel tank (2). Refer to Fuel Tank Draining Procedures.




4. Remove the fuel tank (2) and sender assembly (1). Refer to Fuel Tank Replacement Fuel Tank Replacement.

Disassemble Procedure

1. Note the position of the fuel pump strainer on the fuel pump.
2. Support the pump with one hand and grasp the strainer with the other hand.
3. Rotate the strainer in one direction and pull off the pump. Discard the strainer after inspection.
4. Inspect the fuel pump strainer. Replace the strainer if it has contaminates and clean the fuel tank.
5. Inspect the fuel pump inlet for dirt and debris. If found, replace the pump.

Assemble Procedure

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Push on the outer edge of the ferrule until fully seated.
2. Support the pump with one hand and position the new pump strainer on pump in the same position as noted during disassembly.

Installation Procedure




1. Install the following components:

* A new seal
* The sending assembly
* The lock ring

2. Make sure the lock ring alignment holes fit over the tabs on the tank.

Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the six nuts and washers retaining the fuel sender (2) lock ring.

Tighten the lock ring nuts to 11.5 Nm (100.90 lb in).

4. Install the fuel tank. Refer to Fuel Tank Replacement Fuel Tank Replacement.
5. Add fuel to the tank.
6. Connect the negative battery cable.
7. Inspect for fuel leaks by using the following procedure:

1. Turn the ignition ON for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Again, turn the ignition switch to the ON position.
4. Inspect for fuel leaks.