Removal

Tools Required

- J 34730-1A Fuel Pressure Gauge

- J 39765 Fuel Sender Lock Nut Wrench


REMOVAL PROCEDURE

CAUTION: Provide additional support when a vehicle is on a hoist:

- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.

- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Release / Service and Repair / Fuel Pressure Relief Procedure.

2. Raise the vehicle and suitably support.

3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

IMPORTANT: If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.






4. Disconnect the fuel feed pipe (1) at the in-line fuel filter and return pipe (2) near the in-line fuel filter.






5. Grasp both ends of the fuel feed pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick connect fittings.

CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.






6. Blow out dirt from quick connect fittings, using compressed air.






7. Squeeze the plastic tabs of male end connector of fuel filter.






8. Pull connection apart.

9. Repeat steps 5 through 8 for the other fitting.






10. Disconnect the clamps (3) at the fuel tiller neck (2) and fuel filler neck vent pipe (1) at the fuel tank (4).

11. Remove the fuel filler neck (2) and fuel filler neck vent pipe (1) from the fuel tank (4).






12. Disconnect the fuel sender (1) electrical connector.

13. Remove the exhaust heat shield screws and reposition shield.

NOTICE: Do not bend the fuel tank straps as this may damage the straps.

14. Support the fuel tank and remove the fuel tank retaining strap bolts (2) from the fuel tank retaining strap (3).

15. Lower the fuel tank and disconnect the [1][2]EVAP pipe.

16. Inspect the connectors for dirt and damage. Clean or replace as required.

17. Remove the fuel sender assembly (1) from the fuel tank. Refer to Fuel Sender Assembly Replacement.