Fuel Pump: Service and Repair

FUEL SENDER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J39765-A Fuel Sender Lock Ring Tool

REMOVAL PROCEDURE
1. Remove the fuel tank.




2. Remove the fuel sender shield fasteners.
3. Remove the fuel sender shield.




4. Disconnect the fuel sender electrical connectors.




5. Disconnect the fuel pipes from the fuel sender.

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. Use the J39765-A (1) in order to remove the fuel sender lock ring.

IMPORTANT: The fuel sender assembly will spring up when the fuel sender assembly lock ring is removed.

7. Remove the fuel sender from the fuel tank.

IMPORTANT: The fuel sender must be tipped in order to remove the sender from the fuel tank. Fuel in the sender reservoir must be placed and stored in an approved container.

8. Remove and discard the fuel sender seal.

INSTALLATION PROCEDURE
1. Clean the fuel sender sealing flange.
2. Install the NEW fuel sender seal to the fuel tank.

IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly.

3. Install the fuel sender and the fuel sender lock ring.

IMPORTANT: Do not 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.




4. Use the J39765-A (1) in order to install the fuel sender lock ring.




5. Install the fuel pipes to the fuel sender.




6. Install the fuel sender sensor electrical connectors.




7. Install the fuel sender shield.
8. Install the fuel sender shield nuts.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the nuts to 6 N.m (53 lb in).

9. Install the fuel tank.