Tools Required

J 34730-1A Fuel Pressure Gauge

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.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Drain fuel tank. Refer to Fuel Tank Draining .
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove fuel tank (4). Refer to Fuel Tank Replacement .
5. Remove the locking nut by turning the ring counterclockwise.

Important: The modular fuel sender assembly may spring up from its position. When removing the modular assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. Tip the modular assembly slightly during removal to avoid damage to the float. Have a shop towel ready to absorb any leakage.

6. Remove modular fuel sender assembly (1) from the fuel tank.
7. Remove fuel sender seal (lip). Slide the fuel sender lip seal downward, past the reservoir and carefully over the float arm assembly
8. Discard the fuel sender lip seal.
9. Carefully discard the reservoir fuel into an approved container.

Important: Lip seal should be carefully positioned over the float arm assembly, moved up over the reservoir and half way up the guide posts.

1. Install new lip seal on modular fuel sender assembly. Always use a new lip seal when servicing modular fuel sender unit.
2. Lightly lubricate the inside diameter of the lip seal with clean engine oil.
3. Install modular fuel sender assembly (1) into the fuel tank. Seat the lip seal into tank opening.
4. Align arrow on top of the fuel sender cover to arrow on the fuel tank.

Important: Be sure that the lip seal provides a snug seal between the modular unit and the fuel tank.

5. Slowly apply pressure to the top of the spring loaded sender until the lip seal is flush between the fuel tank and the fuel sender cover.
6. Install the locking ring by turning clockwise.
7. Install the fuel tank. Refer to Fuel Tank Replacement



8. Lower the vehicle.
9. Add fuel to the fuel tank.
10. Reinstall the fuel tank filler pipe cap.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
12. Inspect for fuel leaks.

12.1.

Turn ON the ignition for 2 seconds.

12.2.

Turn OFF the ignition for 10 seconds.

12.3.

Turn ON the ignition.

12.4.

Check for fuel leaks.




13. Install the fuel injector sight shield (1) to the engine.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

14. Install the fuel injector sight shield nuts (2).

Tighten
Tighten the nuts 3 N·m (27 lb in).