Tools Required
CH-47717
Fuel Lock Ring Remover Tool
Removal Procedure
Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur
if an ignition source is present. Never drain or store gasoline or diesel
fuel in an open container, due to the possibility of fire or explosion. Have
a dry chemical (Class B) fire extinguisher nearby.
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.
Caution: Remove the rear compartment floor trim to provide technician contact
with the vehicle's metal surfaces. Failure to remove the rear
compartment floor trim may cause a static electricity discharge to ignite
any fuel vapor resulting in personal injury and vehicle damage.
Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed
areas such as a trunk. To reduce the risk of fire and increased exposure to
vapors:
| • | Use forced air ventilation such as a fan set outside
of the trunk. |
| • | Plug or cap any fuel system openings in order to reduce fuel vapor
formation. |
| • | Clean up any spilled fuel immediately. |
| • | Avoid sparks and any source of ignition. |
| • | Use signs to alert others in the work area that fuel system work
is in process. |
Notice: Cap the fittings and plug the holes when servicing the fuel system in
order to prevent dirt and other contaminants from entering the open
pipes and passages.
Notice: Clean all of the following areas before performing any disconnections
in order to avoid possible contamination in the system:
| • | The fuel pipe connections |
| • | The areas surrounding the connections |
Important:
| • | Always replace the fuel sender assembly O-rings when reinstalling the fuel sender assembly. |
| • | Always maintain cleanliness when servicing fuel system components. |
| • | Do not bend the arm of the fuel gage float while removing the fuel sender assembly. |
- Remove the fuel pump. Refer to
Fuel Pump Replacement
.
- Disconnect the fuel sender insulator connector.
- To disconnect the fuel pump terminal, push the terminal wedge (1) in the insulator.
- Push the wedge (1) outside, then pull the wires to disconnect from the connector.
- Remove the fuel level sensor (1) from the sender housing, then remove the sender housing (2).
- Remove the fuel sender assembly (1).
Installation Procedure
Notice: Always re-attach the fuel lines and fuel filter with all original type
fasteners and hardware.
Do not repair sections of fuel pipes.
- Wind the wires (1) around the sender assembly (2).
Important: Failure to install the fuel sender assembly correctly will result in fuel gauge inaccurate reading.
- Install the sender assembly onto the fuel pump assembly (1).
Important: Failure to install the fuel level sensor correctly will result in fuel level warning lamp inaccurate reading.
- Install the fuel level sensor onto the fuel sender housing.
- Connect the wires into the insulator as follows:
- Connect the fuel sender insulator connector.
- Install the fuel pump. Refer to
Fuel Pump Replacement
.
