Fuel Sender Assembly Replacement

FUEL SENDER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 45722 Fuel Sender Lock Ring Wrench

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.

1. Disconnect the negative battery cable.
2. Relieve the system fuel pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Raise the vehicle. Refer to Vehicle Lifting.
5. Remove the fuel tank.
6. Disconnect the electrical and ventilation connections on the modular fuel sender assembly cover.

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 modular fuel sender assembly O-ring and replace it with a new one.
- Carefully discard the fuel in the reservoir bucket into an approved container.




7. While having an assistant hold the fuel tank, use J 45722 to turn the modular fuel sender assembly lock ring counterclockwise until the ring is released from the fuel tank.
8. Raise the fuel sender assembly out of the tank far enough to access the ventilation harness connection on the underside of the module cover.
9. Disconnect the ventilation harness quick connect before attempting to fully remove the modular fuel sender assembly.

INSTALLATION PROCEDURE




1. Install a new O-ring on the modular fuel sender to tank.
2. Connect the ventilation harness inside the fuel tank to the bottom of the modular fuel sender cover.
3. Align the cover "paddle" or anti-rotation feature with the corresponding feature in the top of the fuel tank.
4. Slowly apply pressure to the top of the spring loaded sender cover until the sender aligns flush with the surface of the tank.
5. Align the locking ring with the matching features on the fuel tank and install the J 45722.
6. Turn the lock ring until the ring seats on the second detent.
7. Connect the electrical and ventilation connections to the modular fuel sender assembly cover.
8. Install the fuel tank.
9. Lower the vehicle.
10. Refill the tank.
11. Connect the negative battery cable.
12. Inspect for fuel leaks through the following steps:
1. Turn the ignition to the ON position for two seconds.
2. Turn the ignition to the OFF position for ten seconds.
3. Turn the ignition to the ON position.
4. Check for fuel leaks.