Fuel Pump: Service and Repair

Fuel Sender Assembly Replacement

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

Removal Procedure




1. Remove the fuel tank. Refer to Fuel Tank Replacement (Removal and Replacement).
2. Remove the fuel feed (1) and evaporative emission (EVAP) (2) lines from the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).





Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

Caution: 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.

Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.




4. Remove the fuel sender assembly (2) and seal (3). Discard the seal.
Warning: Refer to Fuel Storage Warning (Fuel Storage Warning).

5. Clean the fuel sender sealing surfaces (4).





Note:
* Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.
* Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
* Check the lock ring for flatness.

6. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
7. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
8. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

Installation Procedure





Note: Never reuse the old seal or a fuel leak may occur. Always use a NEW seal.

1. Install a NEW seal (3) onto the fuel tank.

Note: Place the fuel pump strainer in a horizontal position when you install the fuel sender in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

2. Install the fuel sender assembly (2).





Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.

Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

3. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.




4. Install the fuel feed (1) and EVAP (2) lines to the sender assembly. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Install the fuel tank. Refer to Fuel Tank Replacement (Removal and Replacement).