Aurora 2001-2003

Removal & Installation

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3.5L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.


    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.

  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the fuel tank.
  8.  
  9. Remove the rear compartment floor trim.
  10.  
  11. Remove the fuel sender access panel bolts.
  12.  
  13. Remove the fuel sender access panel.
    NOTE
    In order to prevent damage, cover the fuel pipe fittings with a shop towel before disconnecting the fuel pipes or removal of the fuel sender retaining ring, in order to catch any fuel that may leak out. Place the towel in an approved container when procedure is completed.

  14.  
  15. Disconnect the fuel sender quick-connect fittings.
  16.  
  17. Disconnect the fuel sender electrical connector.
  18.  
  19. Disconnect the fuel tank pressure sensor electrical connector.
    NOTE
    The modular fuel sender assembly will spring-up when the locking ring is removed.

  20.  
  21. Remove the fuel sender retaining ring using special tool J39765 or a suitable spanner.
    WARNING
    Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.


    CAUTION
    When removing the fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender is full of fuel. The fuel sender must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the fuel sender is removed from the fuel tank.

  22.  
  23. Remove the fuel sender assembly.
  24.  
  25. Clean the fuel sender sealing surfaces.
  26.  
  27. Inspect the fuel sender sealing surfaces.
  28.  

To install:


WARNING
Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of the float arm.

  1. Position the new fuel sender seal on the fuel tank with a new seal.
  2.  
  3. Install the fuel sender assembly and the fuel sender lock ring using special tool J39765 or a suitable spanner.
  4.  
  5. Connect the quick-connect fittings at the fuel sender.
  6.  
  7. Connect the fuel sender electrical connector.
  8.  
  9. Connect the fuel tank pressure sensor electrical connector.
  10.  
  11. Add fuel to the fuel tank.
  12.  
  13. Install the fuel tank filler pipe cap.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Inspect for leaks.
    1. Turn ON the ignition for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  18.  
  19. Install the fuel sender access panel.
  20.  
  21. Install the fuel sender access panel bolts and tighten to 18 inch lbs. (2 Nm)
  22.  
  23. Install the rear compartment floor trim.
  24.  
  25. Install the fuel injector sight shield.
  26.  

4.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.


    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.

  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the fuel tank.
  8.  
  9. Remove the rear compartment floor trim.
  10.  
  11. Remove the fuel sender access panel bolts.
  12.  
  13. Remove the fuel sender access panel.
    NOTE
    In order to prevent damage, cover the fuel pipe fittings with a shop towel before disconnecting the fuel pipes or removal of the fuel sender retaining ring, in order to catch any fuel that may leak out. Place the towel in an approved container when procedure is completed.

  14.  
  15. Disconnect the fuel sender quick-connect fittings.
  16.  
  17. Disconnect the fuel sender electrical connector.
    NOTE
    The modular fuel sender assembly will spring-up when the locking ring is removed.

  18.  
  19. Disconnect the fuel tank pressure sensor electrical connector.
    NOTE
    The modular fuel sender assembly will spring-up when the locking ring is removed.

  20.  
  21. Remove the fuel sender retaining ring using special tool J39765 or a suitable spanner.
    WARNING
    Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.


    CAUTION
    When removing the fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender is full of fuel. The fuel sender must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the fuel sender is removed from the fuel tank.

  22.  
  23. Remove the fuel sender assembly.
  24.  
  25. Clean the fuel sender sealing surfaces.
  26.  
  27. Inspect the fuel sender sealing surfaces.
  28.  

To install:


WARNING
Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of the float arm.

  1. Position the new fuel sender seal on the fuel tank with a new seal.
  2.  
  3. Install the fuel sender assembly and the fuel sender lock ring using special tool J39765 or a suitable spanner.
  4.  
  5. Connect the quick-connect fittings at the fuel sender.
  6.  
  7. Connect the fuel sender electrical connector.
  8.  
  9. Connect the fuel tank pressure sensor electrical connector.
  10.  
  11. Add fuel to the fuel tank.
  12.  
  13. Install the fuel tank filler pipe cap.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Inspect for leaks.
    1. Turn ON the ignition for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  18.  
  19. Install the fuel sender access panel.
  20.  
  21. Install the fuel sender access panel bolts and tighten to 18 inch lbs. (2 Nm)
  22.  
  23. Install the rear compartment floor trim.
  24.  
  25. Install the fuel injector sight shield.
  26.  

 
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