Fuel Gauge Sender: Service and Repair
Removal ProcedureCAUTION: 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.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure.
3. Drain fuel tank.
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 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 slot on 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 snap ring into 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:
1. Turn the ignition to the ON position for 2 seconds.
2. Turn the ignition to the OFF position for 10 seconds.
3. Turn the ignition to the ON position
4. Check for fuel leaks.