Fuel Sender Assembly Replacement

FUEL SENDER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 39765 Fuel Sender Lock Nut Wrench

REMOVAL PROCEDURE




1. Disconnect the negative battery cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Remove the fuel tank.
5. Remove the retaining ring from the fuel sender assembly using the J 39765

NOTE: 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.

6. Remove the fuel sender assembly and the seal. Discard the seal.
7. Clean the fuel sender sealing surfaces.

CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.

INSTALLATION PROCEDURE




1. Install the new seal on the fuel tank.

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.

2. Install the fuel sender assembly into the fuel tank.

IMPORTANT: The fuel strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel strainer does not block full travel of the float arm.

3. Install the retaining ring to the fuel sender assembly using the J 39765
4. Install the fuel tank.
5. Refill the fuel tank.
6. Tighten the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks:
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.