Installation Procedure

NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

Position the new fuel sender assembly O-ring (2) on the fuel sender assembly (1). See Figure.
Install the fuel sender assembly (1) into the fuel tank (3).
Install the fuel sender assembly hold down plate (1). See Figure.
NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Secure the fuel sender assembly hold down plate with eight bolts (2).
Tighten

Tighten the fuel sender assembly hold down plate bolts to 4 Nm (53 lb in).
Install the fuel pipe (2) to the fuel sender fitting. See Figure.
Secure the fuel pipe (2) with the retaining clip (1).
Connect the fuel sender assembly electrical connector (1). See Figure.
Connect the negative battery cable.
Tighten

Tighten the negative battery cable terminal retainers to 15 Nm (11 lb ft).
Pressurize the fuel system and check for leaks.
Inspect the fuel sender access panel (1) butyl caulk seal. See Figure.
Replace any missing butyl caulk as necessary.
Install the fuel sender assembly access panel (1) to the rear seat floor.
Relocate the carpet under the seat and left sill plate area.
Install the left side door opening sill plate.
Install the rear seat bottom cushion.