REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Relieve the fuel pressure from the vehicle, as is explained earlier in this section.
- Disconnect the negative cable at the battery.
- Raise and support the car.
- Drain the tank. There is no drain plug, remaining fuel in the tank must be siphoned through the fuel feed line (the line to the fuel pump), because of the restrictor in the filler neck.
- Disconnect the hose and the vapor return hose from the sending unit fittings.
- Remove the ground wire screw.
- Unplug the sending unit electrical connector.
- Detach the vent hose. Disconnect any quick connect fittings.
- If necessary, remove the exhaust pipe heat shield.
- With an assistant supporting the tank, unbolt the retaining straps, and lower and remove the tank.
- Remove the sending unit from the tank. Then remove the tank insulator pads, making note of where they are to be placed on the new tank.
- Attach the insulator pads to the new tank, then install the sending unit.
- With an assistant, position the tank and support it while attaching the retaining strap mounting bolts.
- Tighten the front retaining strap bolts to 25 ft. lbs. (34 Nm) and the rear to 17 ft. lbs. (23 Nm).
- If applicable, install the exhaust pipe heat shield.
- Attach any quick connect fittings and all the EVAP connecting hoses.
- Connect the sending unit electrical harness. Install the fuel filler vent hose and clamp, tighten the clamp to 22 inch lbs. (3 Nm).
- Lower the vehicle.
- Add fuel to the tank and install the filler cap.
- Check for leaks. If non are present, connect the negative battery cable.
SENDING UNIT REPLACEMENT
See Figure 4
The fuel gauge sending unit is attached to the fuel pump on cars with an electric in-tank pump. The following procedure is for pump and sending unit removal and installation. If the vehicle has a pump mounted on the engine, the basic steps will still lead you through sending unit replacement. Be extremely cautious of sparks or flame when working around the fuel pump. NEVER apply battery power to a used fuel pump out of the fuel tank.
- Relieve the fuel system pressure, then disconnect the negative battery cable.
- Raise and support the vehicle safely. Drain the fuel tank.
- Disconnect wiring from the tank, then remove the ground wire retaining screw from under the body.
- Disconnect all hoses from the tank.
- Support the tank on a jack and remove the retaining strap nuts.
- Lower the tank and remove it from the vehicle.
- Remove the fuel gauge/pump retaining ring using a suitable spanner wrench.
- Remove the gauge unit and the pump.
- Install the gauge unit and the pump.
- Install the fuel gauge/pump retaining ring using a suitable spanner.
- Raise the tank and install it to the vehicle.
- Support the tank on a jackstand and install the retaining strap nuts.
- Connect the hoses to the tank.
- Connect the electrical connectors and the ground wire, if equipped.
- Lower the vehicle.
- Fill the fuel tank.
- Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Turn the ignition switch back to the ON position and check for fuel leaks.