Removal & Installation (Deville & Seville - 4.6L)
CAUTION:
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
CAUTION:
Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash. Drain the fuel tank to at least 3/4 of a tank before removing the fuel sender retaining ring or fuel sender access panel in order to avoid possible fuel spillage. Failing to follow this procedure could result in personal injury.
NOTE:
Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections The hose connections The areas surrounding the connections.
NOTE:
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. Always replace the fuel sender "O" ring when reinstalling the fuel sender assembly.
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.
- Relieve the fuel system fuel pressure. See FUEL PRESSURE RELIEF . Drain the fuel tank to at least three-quarters of a tank full.
- Remove the spare tire cover, the jack, and the spare tire. Remove the rear compartment floor trim to avoid damage from fuel spillage.
- Remove the rear compartment floor trim (1). Remove the bolts from the fuel sender access panel (2). See Fig 1.
- Disconnect the quick-connect fittings at the fuel sender assembly. Disconnect the electrical connector at the fuel sender. Disconnect the electrical connector at the fuel tank pressure sensor.
- Remove the fuel sender retaining ring using the Fuel Sender Locknut Wrench (J-39765). See Fig 2.
- Pull the fuel sender straight up while pumping the fuel from the reservoir. Clean the fuel sender assembly "O" ring sealing surfaces. Inspect the fuel sender assembly "O" ring sealing surfaces.
- Reinstall the fuel sender assembly and the fuel sender assembly retainer using the Fuel Sender Locknut Wrench (J-39765) (1). Install the quick-connect fittings at the fuel sender assembly. Connect the electrical connector at the fuel tank pressure sensor. Connect the electrical connector at the fuel sender assembly. Connect the negative battery cable.
- Inspect for leaks. Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Check for fuel leaks. Reinstall the fuel sender access panel. Tighten the fuel sender access panel bolts to specification. See TORQUE SPECIFICATIONS .
- Reinstall the rear compartment floor trim. Reinstall the spare tire, the jack, and the spare tire cover. Add fuel to the fuel tank. Install the fuel tank filler pipe cap. Install the rear seat cushion. Install the fuel injector sight shield to the engine. Install the fuel injector sight shield nuts. Tighten the nuts to specification.
CAUTION:
Remove the rear compartment floor trim to provide technician contact with the vehicle's metal surfaces. Failure to remove the rear compartment floor trim may cause a static electricity discharge to ignite any fuel vapor resulting in personal injury and vehicle damage.
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.
CAUTION:
When removing the fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The fuel sender assembly 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 assembly is removed from the fuel tank.
CAUTION:
The fuel sender assembly will spring-up when the locking ring is removed.
CAUTION:
Always replace the fuel sender "O" ring when reinstalling the fuel sender assembly. Position the NEW fuel sender assembly "O" ring on the fuel tank. 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 float arm.