Fuel Tank Unit: Service and Repair

Fuel Sender Assembly Replacement

REMOVAL PROCEDURE

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.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

IMPORTANT:
^ Always maintain cleanliness when servicing fuel system components.
^ Important always replace the fuel sender O-rings when reinstalling the fuel sender assembly.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle.
4. Remove the fuel tank.
5. 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.
6. Disconnect the quick-connect fittings at the fuel sender assembly.
7. Remove the fuel sender assembly retaining snap ring, the fuel sender assembly and the O-ring from the fuel tank.
8. Discard the fuel sender assembly O-ring.

INSTALLATION PROCEDURE

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

Do not repair sections of fuel pipes.

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

IMPORTANT: 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.

3. Install the fuel sender assembly and the fuel sender assembly retaining snap ring.
4. Reconnect the quick-connect fittings at the fuel sender assembly.
5. Reinstall the fuel tank.
6. Lower the vehicle.
7. Add fuel and install the fuel tank filler pipe cap.
8. Reconnect the negative battery cable.
9. Inspect for leaks:
9.1. Turn the ignition switch ON for 2 seconds.
9.2. Turn the ignition switch OFF for 10 seconds.
9.3. Turn the ignition switch ON.
9.4. Check for fuel leaks.