REMOVAL & INSTALLATION
See Figure 1Gasoline Engines
- Relieve the fuel system pressure.
- Disconnect the negative battery cable.
- Remove the fuel from the fuel tank by pumping it out through the filler neck. Clean up any fuel spillage immediately.
- Raise and support the vehicle safely and remove the fuel filler tube (neck). On all wheel drive vehicles, remove the exhaust system and rear axle assembly.
- Support the fuel tank and remove the fuel tank straps, lower the fuel tank enough to be able to remove the fuel lines, electrical connectors and vent lines from the tank.
- Remove the fuel tank from under the vehicle and place it on a suitable work bench. Remove any dirt around the fuel pump attaching flange.
- Turn the fuel pump locking ring counterclockwise and remove the lock ring.
- Remove the fuel pump from the fuel tank and discard the flange gasket.
- On all wheel drive vehicles, partially raise the sender unit and disconnect the jet pump line and resistor electrical connector. Remove the fuel pump and bracket assembly with seal gasket. Remove the seal gasket and replace with new. Remove the jet pump assembly.
- Clean fuel pump mounting flange and fuel tank mounting surface and seal ring groove.
- Lightly coat the new seal ring gasket with a suitable lubricant compound part No. C1AZ-19590-B or equivalent, to hold the gasket in place during installation.
- All wheel drive vehicles only, install jet pump assembly and retaining screw.
- Install fuel pump and sender. Ensure that nylon filter is not damaged and that locating keys are in keyways and seal ring remains in place.
- All wheel drive vehicles only, connect jet pump line and electrical connector to resistor. Ensure locating keyways and seal ring remain in place.
- Hold assembly in place and install locking ring finger-tight. Ensure that all locking tabs are under tank lock ring tabs.
- Secure unit with locking ring by rotating ring clockwise using fuel sender wrench tool D84P-9275-A or equivalent, until ring stops against stops.
- Remove tank from bench to vehicle and support tank while connecting fuel lines, vent line and electrical connectors to appropriate places.
- Install tank in vehicle and secure with retaining straps.
- All wheel drive vehicles only, install rear axle assembly and exhaust system.
- Lower vehicle and install fuel in tank. Check for leaks.
- Connect negative battery cable.
- Check fuel pressure.
- Remove the pressure gauge, start the engine and recheck for fuel leaks. Correct all fuel leaks immediately.
- Disconnect the negative battery cable from the battery in the luggage compartment.
- Raise the rear of the vehicle and safely support it on jackstands.
- Disconnect the gas fill and breather lines from the tank. Disconnect the fuel feed, return and breather lines from the front of the tank, plug these lines.
- Remove the 2 mounting bolts at the top rear of the tank while supporting the tank on a piece of wood and a floor jack. Lower and remove the gas tank.
- Raise the fuel tank to the vehicle, and secure by installing the mounting bolts at the rear of the tank.
- Connect the gas fill, breather hose, fuel fill and return lines.
- Lower the vehicle.
- Connect the negative battery cable.
- Start vehicle and check for leaks.
SENDING UNIT REPLACEMENT
On all Tempo/Topaz models, the fuel gauge sender is located in the fuel tank.
But the year, fuel delivery method and fuel used in the vehicle will determine the type of fuel sender incorporated into the vehicle.
Carbureted vehicles use a mechanical fuel pump at the engine. As a result this vehicle uses an electrical sender unit in the fuel tank. Diesel vehicles also use a mechanical fuel pump in the engine compartment and also use an electrical pump in the tank.
Fuel injected vehicles utilize a more complicated fuel sender unit. This type of fuel registry unit incorporates the fuel pump with the fuel sender. The sender unit is not individually serviceable from the pump. Also the sender uses a magnetic method of delivering information as opposed to an electrical method used by carbureted and diesel vehicles.
Before replacing a fuel sending unit, determine whether a sender, or a sender/pump unit is needed to complete the procedure.
- Disconnect the negative battery terminal.
- Remove the fuel from the fuel tank.
- Remove the tank from the vehicle.
- Disconnect the fuel sender/pump sender wire harness.
- Using the appropriate tools, remove the sending/pump sender unit from the vehicle, by turning the collar counterclockwise. Carefully lift the sender/pump sender out of the tank.
- Check the gasket used to seal and secure the sender/ pump sender, and replace if necessary.
- Carefully install the sender/pump sender into the fuel tank with a new gasket. Use care not to bend the rod with the float at the end, this could effect fuel gauge accuracy.
- Tighten the collar using the appropriate tool.
- Connect the wire harness to the sender/pump sender.
- Position and secure the fuel tank to the vehicle.
- Lower vehicle, add fuel, connect the negative battery terminal and check for proper fuel gauge function.