Fuel Tank Unit: Service and Repair

Removal Procedure

Caution: 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.

Notice: Numbers in text correspond to numbered components in image.

1. Remove the negative battery cable.

2. Relieve system fuel pressure. Refer to Fuel Pressure Release.

3. Drain fuel tank. Refer to Fuel Tank Draining.

4. Remove the fuel tank. Refer to Fuel Tank Assembly.

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 full of fuel. It 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.

5. While holding the modular fuel sender assembly down, remove the snap ring from designated slots located on the retainer.

6. Remove the fuel sender assembly from the fuel tank.


Installation Procedure

1. Install a new O-ring on modular fuel sender (3) to tank.

2. Align tab on front of sender (2) with slot on front of retainer snap ring.

3. Slowly apply pressure to top of spring loaded sender until sender aligns flush with retainer on tank.

Important: Be sure that the snap ring is fully seated within the tab slots.

4. Insert snap ring (1) into designated slots.

5. Install the fuel tank.

6. Lower vehicle.

7. Refill tank.

8. Connect the negative battery cable.

9. Inspect for fuel leaks through the following steps:

9.1. Turn the ignition to the ON position for two seconds

9.2. Turn the ignition to the OFF position for ten seconds.

9.3. Turn the ignition to the ON position

9.4. Check for fuel leaks.