Fuel Sender Assembly Replacement

REMOVAL PROCEDURE

TOOLS REQUIRED
J 39765 Fuel Sender Lock Nut Wrench

CAUTION:
^ Refer to Gasoline/Gasoline Vapors Caution in Service Precautions.
^ Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.
^ Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

NOTE: Refer to Cover and Plug Openings Notice in Service Precautions.

IMPORTANT:
^ Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.
^ The modular fuel sender assembly will spring-up when the snap ring is removed.
^ When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The modular 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 modular fuel sender assembly is removed from the fuel tank.
^ Always maintain cleanliness when servicing the fuel system components.




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair
2. Remove the rear compartment trim panel.
3. Remove the nuts retaining the fuel sender access panel.
4. Remove the fuel sender access panel.
5. Disconnect the fuel sender electrical connectors.
6. Clean the fuel pipes and the fuel sender assembly to prevent fuel contamination during the removal.
7. Disconnect the quick-connect fittings at the fuel sender assembly.




8. Use the J 39765 fuel sender lock nut wrench to remove the lock ring retaining the fuel sender.
9. Remove the modular fuel sender assembly.
10. Clean and inspect the O-ring sealing surfaces of the fuel sender assembly.

INSTALLATION PROCEDURE

NOTE: Refer to Fuel System Ground Notice in Service Precautions.

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, ensure that the fuel pump strainer does not block full travel of float arm.
^ Ensure that the snap ring retaining the fuel sender assembly is fully seated within the tab slots on the fuel tank.




1. Position the new fuel sender assembly O-ring on the fuel tank.

IMPORTANT: The Fuel Sender Assembly is spring loaded, it will be necessary to hold the sender in place.

2. Install the fuel sender assembly into the fuel tank.
3. Use the J 39765 fuel sender lock nut wrench to install the snap ring retaining the fuel sender assembly.
4. Connect the fuel sender assembly electrical connectors.
5. Install the quick-connect fittings at the fuel sender assembly.
6. Connect the negative battery cable.
7. Perform the following procedure to check for fuel leaks:
7.1. Turn the ignition switch to the ON position for 2 seconds.
7.2. Turn the ignition switch to the OFF for 10 seconds.
7.3. Turn the ignition switch to the ON position again.
7.4. Visually inspect the fuel system for fuel leaks.




8. Install the fuel sender access panel.

NOTE: Refer to Fastener Notice in Service Precautions.

9. Install the nuts (7) retaining the fuel sender access panel.

Tighten
Tighten the nuts to 10 N.m (8 lb ft)

10. Install the rear compartment trim panel.
11. Install the fuel injector sight shield.