Fuel Sender Assembly Replacement

CAUTIONS:
- 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.

- Important always replace the fuel sender O-rings when reinstalling the fuel sender assembly.

SPECIAL TOOLS REQUIRED (or equivalents)
- Fuel Tank Sending Unit Wrench J 39348 Fuel Sender Spanner Wrench.

REMOVE OR DISCONNECT
1. Relieve the fuel system fuel pressure, refer to Fuel Pressure Release.
2. Drain the fuel tank, refer to Fuel Tank / Fuel Tank Draining.
3. Fuel tank, refer to Fuel Tank.
4. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
5. Quick-connect fittings at the fuel sender assembly, refer to Fuel Line Coupler.
6. Using the Fuel Tank Sending Unit Wrench J 39348 Fuel Sender Spanner Wrench, remove the fuel sender assembly locking nut, the fuel sender assembly and the O-ring from the fuel tank.
7. Discard the fuel sender assembly O-ring.

INSTALL OR CONNECT
1. Clean the fuel sender assembly O-ring sealing surfaces.
2. Position the new fuel sender assembly O-ring on the fuel tank.

NOTE: 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.

3. Fuel sender assembly and the fuel sender assembly locking nut using the Fuel Tank Sending Unit Wrench J 39348 Fuel Sender Wrench.
4. Quick-connect fittings at the fuel sender assembly.
5. Fuel tank.
6. Lower the vehicle.
7. Add fuel and install the fuel tank filler pipe cap.
8. Negative battery cable.
9. Inspect for leaks:
a. Turn the ignition switch to the ON position for 2 seconds.
b. Turn the ignition switch to the OFF for 10 seconds.
c. Turn the ignition switch to the ON position.
d. Check for fuel leaks.