Do not allow smoking or the use of open flames in the area where work on the
fuel or EVAP system is taking place. Anytime work is being done on the
fuel system, disconnect the negative battery cable, except for those tests where battery
voltage is required.
Remove the fuel tank and fuel pump module.
Remove the electrical connector from the fuel level sending unit by disengaging
the locking tab and pulling the connector from the sender.
Important
The fuel pump assembly is only serviced as a module without the sender unit.
The inlet filter can be cleaned with mineral spirits, however, it cannot be replaced.
Important
The fuel pump module to tank seal must always be replaced whenever the module
is removed from the fuel tank. The correct seal is green in color. Do not use the
older black seal.
Grasping the fuel pump module in both hands and placing both thumbs at the bottom
of the fuel sending unit, firmly press the sender toward the top of the module to
disengage the bottom attachment tang.
Position the sender unit tank in the locator
slot and snap the unit into place.
Important
Verify that the float arm on the sender unit maintains the correct relationship
to the pump module by standing the module on a flat, horizontal surface and measuring
the distance between the surface and the bottom of the float. Use a 5/32 in.
diameter drill as a gage. The gage must freely pass between the float and the horizontal
surface with no more than 1/16 in. clearance. Refer to
Fuel Sender Assembly Replacement
.
To verify the function and calibration of the sending unit, refer to "Fuel Gage
and Tank Sender Unit Calibration and Electrical Circuit" in this service manual.
Install the electrical connector from the pump module to the sender unit. Push
firmly to engage.
Install the fuel pump module and tank.
Perform the Service Bay Diagnostic Test for the evaporative emission
system using the Tech-2. This test will verify the integrity of the vapor handling
areas of the fuel system. Refer to Service Stall System (SSS) user guide.
