Fuel Sender Assembly Replacement

REMOVAL PROCEDURE

Tools Required:
^ J 34730 Fuel Pressure Gauge
^ J 35731 Fuel Sender Spanner Wrench

NOTICE: 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.

NOTICE: Replace the fuel sender O-rings when re-installing the fuel sender in order to avoid damage to the fuel sender assembly.




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Release / Service and Repair / Fuel Pressure Relief Procedure.




2. Drain the fuel tank (1). Refer to Fuel Tank / Service and Repair / Fuel Tank Draining.

Fuel Tank Assembly:

3. 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.
4. Remove the fuel tank (2). Refer to Fuel Tank / Service and Repair.
5. Remove the quick-connect fittings at the fuel sender assembly. Refer to Fuel Line Coupler / Service and Repair.


DISASSEMBLE PROCEDURE

Description:

1. Remove the fuel sender assembly retaining cam, using the J 35731 Fuel Sender Spanner Wrench.
2. Remove the fuel sender assembly and the O-ring from the fuel tank.
3. Discard the fuel sender assembly O-ring.
4. Clean the fuel sender assembly O-ring sealing surfaces.
5. Inspect the fuel sender assembly O-ring sealing surfaces.


ASSEMBLE PROCEDURE

IMPORTANT: 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.

1. Position the new fuel sender assembly O-ring on the fuel tank.
2. Assemble the fuel sender assembly and the fuel sender assembly retainer cam using the J 35731 Fuel Sender Spanner Wrench.


INSTALLATION PROCEDURE

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

Do not repair sections of fuel pipes.

1. Install the fuel tank (2). Refer to Fuel Tank / Service and Repair.
2. Lower the vehicle.
3. Add fuel to the vehicle.




4. Install the fuel tank filler pipe cap.
5. Install the negative battery cable.
6. Inspect for leaks.
6.1. Turn the ignition switch to the On position for 2 seconds.
6.2. Turn the ignition switch to the Off for 10 seconds.
6.3. Turn the ignition switch to the On position.
6.4. Check for fuel leaks.