Modular Fuel Sender Assembly

Subassemblies Of Modular Fuel Sender:

Modular Fuel Sender To Tank:

CAUTION:
Always replace fuel sender assembly O-ring when reinstalling fuel sender assembly.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Relieve system fuel pressure. Refer to "Fuel System Relief Procedure" in this section.
3. Drain fuel tank.
4. Fuel tank.
5. While holding the modular fuel sender assembly down, remove the snap ring from designated slots located on the retainer.

NOTICE: 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.

INSTALL OR CONNECT
1. New O-ring on modular fuel sender to tank.
2. Align tab on front of sender with slot on front of retainer snap ring.
3. Slowly apply pressure to top of spring loaded sender until sender aligns flush with retainer on tank.
4. Insert snap ring into designated slots.

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

5. Fuel tank.
6. Lower vehicle.
7. Refill tank.

Inspect
a. Turn ignition to "ON" position for two seconds, then turn to "0FF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.

FUEL PUMP STRAINER REPLACEMENT

REMOVE OR DISCONNECT
1. Relieve fuel system pressure. Refer to "Fuel System Pressure Relief" in this section.
2. Drain fuel tank. Refer to "Draining Fuel Tank" in this section.
3. Fuel tank. Refer to "Fuel Tank Replacement" in this section.
4. Fuel sender assembly. Refer to "Modular Fuel Sender Assembly" in this section.
5. Note strainer position for future reference.
6. Support the reservoir with one hand and grasp the strainer with the other hand.
7. Using a screwdriver to pry the strainer ferrule off the reservoir.
8. Discard the strainer.

INSTALL OR CONNECT
1. New strainer to reservoir.
2. Support the reservoir with one hand and grasp the strainer with the other hand twisting strainer into position noted in step 5.
3. Fuel sender assembly.
4. Fuel tank.
5. Refill tank.

Inspect
Turn ignition to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.

FUEL LEVEL SENSOR REPLACEMENT

REMOVE OR DISCONNECT
1. Relieve fuel system pressure.
2. Drain fuel tank.
3. Fuel tank.
4. Fuel sender assembly.
5. Bumper from modular fuel sender assembly.
6. Fuel level sensor

INSTALL OR CONNECT
1. Fuel level sensor to modular fuel sender.
2. Bumper to modular fuel sender assembly.
3. Fuel sender assembly.
4. Fuel tank.
5. Refill tank.

Inspect
Turn ignition to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.

FUEL PUMP REPLACEMENT
The fuel pump is not serviced separately. The modular sender assembly must be serviced as a complete unit.