Fuel Pump: Service and Repair

FUEL SENDER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 39765 Fuel Sender Locknut Wrench

REMOVAL PROCEDURE
1. Remove the fuel tank.




2. Disconnect the fuel sender electrical connectors.

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.

3. Disconnect the fuel and EVAP pipes from the fuel sender.
4. Remove the fuel sender assembly retaining ring using the J 39765.
5. Remove the fuel sender assembly and the seal. Discard the seal.

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.

6. Clean the fuel sender sealing surfaces.

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 pump 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 pump strainer does not block full travel of the float arm.

3. Install the fuel sender assembly retaining ring using the J 39765.
4. Connect the fuel and EVAP pipes to the fuel sender.
5. Connect the fuel sender electrical connectors.
6. Install the fuel tank.