Tracker 2000-2004

Removal & Installation

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NOTE
The fuel pump and the fuel level sensor are integral parts of the fuel sender assembly. In order to service any of these components, replace the fuel level sender assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel filler hose and vent hose
     
    Fuel tank inlet valve and drain the fuel tank
     
    Fuel filter inlet hose
     
    Evaporative Emissions (EVAP) vapor hose
     
    Fuel return line
     
    Fuel tank skidplate
     
    Fuel pump connector
     
    Fuel tank pressure sensor connector
     
    Fuel tank
     
    Fuel level sending unit
     

  6.  

To install:

  1. Install or connect the following:

    Fuel level sending unit with a new seal. Tighten the bolts to 44 inch lbs. (5 Nm).
     
    Fuel tank. Tighten the strap bolts to 37 ft. lbs. (50 Nm).
     
    Fuel tank pressure sensor connector
     
    Fuel pump connector
     
    Fuel tank skidplate
     
    Fuel return line
     
    EVAP vapor hose
     
    Fuel filter inlet hose
     
    Fuel tank inlet valve and drain the fuel tank
     
    Fuel filler hose and vent hose
     
    Negative battery cable
     

  2.  
  3. Fill the fuel tank.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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