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Fuel Sender Assembly Replacement (Long wheel base)



FUEL SENDER ASSEMBLY REPLACEMENT (LONG WHEEL BASE)

TOOLS REQUIRED
J 39765 Fuel Sender Lock Nut Wrench

REMOVAL PROCEDURE




1. Remove the fuel tank.

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.

2. Disconnect the fuel sender electrical connections (3)
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. Disconnect the fuel supply pipe quick-connect fitting (4) at the fuel sender assembly.
5. Disconnect the evaporative emission (EVAP) pipe quick-connect fittings (5, 6) at the fuel sender assembly.
6. Use the J 39765 in order to remove the fuel sender assembly retaining ring (1).
7. Remove the fuel sender assembly (2) and the seal (7) from the fuel tank.

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.

8. Discard the fuel sender assembly seal.
9. Clean the fuel sender assembly sealing surfaces.

INSTALLATION PROCEDURE




1. Position the new fuel sender assembly seal (7) 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 (2) into the fuel tank.

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.

3. Use the J 39765 in order to install the fuel sender assembly retaining ring (1).
4. Connect the fuel supply pipe quick-connect fitting (4) at the fuel sender assembly.
5. Connect the EVAP quick-connect fittings (5, 6) at the fuel sender assembly.
6. Connect the fuel sender electrical connections (3)
7. Install the fuel tank.
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