Fuel Sender Assembly Replacement Replacement

Notice: 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.

Notice: Replace the fuel sender O-rings when re-installing the fuel sender in order to avoid damage to the fuel sender assembly.

Tools Required

J 35731 Fuel Sender Spanner Wrench.

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
4. Remove the fuel tank (2). Refer to Fuel Tank Replacement .
5. Remove the quick-connect fittings at the fuel sender assembly. Refer to Servicing Quick Connect Fittings .

1. Remove the fuel sender assembly retaining cam, using the J 35731 Fuel Sender Spanner Wrench.
2. Remove the fuel sender assembly and the O-ring from the fuel tank.
3. Discard the fuel sender assembly O-ring.
4. Clean the fuel sender assembly O-ring sealing surfaces.
5. Inspect the fuel sender assembly O-ring sealing surfaces.

Important: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

1. Position the new fuel sender assembly O-ring on the fuel tank.
2. Assemble the fuel sender assembly and the fuel sender assembly retainer cam using the J 35731 Fuel Sender Spanner Wrench.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the fuel tank (2). Refer to Fuel Tank Replacement .
2. Lower the vehicle.
3. Add fuel and install the fuel tank filler pipe cap.
4. Install the negative battery cable.
5. Inspect for leaks.

5.1.	Turn the ignition switch to the On position for 2 seconds.

5.2.	Turn the ignition switch to the Off for 10 seconds.

5.3.	Turn the ignition switch to the On position.

5.4.	Check for fuel leaks.