Fuel Tank Unit: Service and Repair
FUEL SENDER ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
CAUTION:
^ In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.
^ Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Remove the pickup box.
4. Disconnect the fuel sender electrical connectors.
5. Disconnect the fuel sender fuel and evaporative emission (EVAP) pipes.
Important:
^ The modular fuel sender assembly may spring up from its position.
^ When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is lull of fuel. The fuel sender assembly must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one.
^ Carefully discard the reservoir fuel into an approved container.
6. While holding the modular fuel sender assembly down, remove the snap ring from designated slots (1) located on the retainer.
INSTALLATION PROCEDURE
1. Install a new O-ring on the modular fuel sender to the tank.
2. Align the tab on front of the modular sender with slot on front of the retainer snap ring.
3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.
IMPORTANT: Be sure that the snap ring is fully seated within the tab slots.
4. Insert snap ring into designated slots (1).
5. Connect the fuel sender fuel and EVAP pipes.
6. Connect the fuel sender electrical connectors.
7. Connect the negative battery cable.
8. Inspect for fuel leaks through the following steps:
8.1. Turn ON the ignition for two seconds.
8.2. Turn OFF the ignition for ten seconds.
8.3. Turn ON the ignition.
8.4. Check for fuel leaks.
9. Install the pickup box.