Fuel Gauge Sender: Service and Repair

Fuel Sender Assembly Replacement




REMOVAL PROCEDURE

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.
^ Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
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.

IMPORTANT:
^ The modular fuel sender assembly may spring up from its position.
^ When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one.
^ Carefully discard the reservoir fuel into an approved container.

5. While holding the modular fuel sender assembly down, remove the snap ring from the designated slots (1) located on the retainer.

INSTALLATION PROCEDURE

1. Install a new O-ring on the modular fuel sender to the tank.
2. Align the tab on front of the modular sender with the slot on the front of the retainer snap ring.
3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.

IMPORTANT: Be sure that the snap ring is fully seated within the tab slots.

4. Insert the snap ring into the designated slots (1).
5. Install the fuel tank.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

6. Lower the vehicle.
7. Refill the fuel tank.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

8. Connect the negative battery cable.
9. Inspect for fuel leaks through the following steps:
9.1. Turn On the ignition, with the engine OFF for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn On the ignition, with the engine OFF.
9.4. Inspect for fuel leaks.