Fuel Sender Assembly Replacement Replacement

Tools Required

Refer to J 39348 Fuel Tank Sender Wrench

Important: Always replace fuel sender assembly lip seal when reinstalling fuel sender assembly.

1. Relieve the fuel system pressure, refer toFuel Pressure Relief Procedure .
2. Drain fuel tank refer to Fuel Tank Replacement (Draining) .
3. Remove fuel tank (3), refer to Fuel Tank Replacement .
4. Remove the locking nut using J 39348 by turning counterclockwise.

Important: The modular fuel sender assembly may spring up from its position. When removing the modular assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. Tip the modular assembly slightly during removal to avoid damage to the float. Have a shop towel ready to absorb any leakage.

5. Remove modular fuel sender assembly from the fuel tank (4).
6. Remove fuel sender seal (lip). Slide the fuel sender lip seal downward, past the reservoir and carefully over the float arm assembly
7. Discard the fuel sender lip seal.
8. Carefully discard the reservoir fuel into an approved container.

1. Install new lip seal on modular fuel sender assembly. Always use a new lip seal when servicing modular fuel sender unit.

Important: Lip seal should be carefully positioned over the float arm assembly, moved up over the reservoir and half way up the guide posts.

2. Lightly lubricate the inside diameter of the lip seal with engine oil.
3. Install modular fuel sender assembly (4) into the fuel tank (3).

Seat lip seal into tank opening.

4. Align arrow on top of the fuel sender cover to arrow on the fuel tank.
5. Slowly apply pressure to the top of the spring loaded sender until the lip seal is flush between the fuel tank and the fuel sender cover.

Tighten
Tighten the locking nut and tighten locking nut to 50 N·m 37 lb ft).

Be sure that the lip seal provides a snug seal between the modular unit and the fuel tank.

6. Install the fuel tank, refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement Fuel Level Sensor Replacement

1. Relieve fuel system pressure, refer to Fuel Pressure Relief Procedure .
2. Drain fuel tank, refer to Fuel Tank Replacement (Draining) .
3. Remove fuel tank, refer to Fuel Tank Replacement .
4. Remove Modular fuel sender assembly, refer to Fuel Sender Assembly Replacement .
5. Remove the external strainer.
6. Use a screwdriver to carefully pry the strainer (3) ferrule off the reservoir (1).
7. Check the strainer position for later reinstallation.
8. Discard the strainer.
9. Remove Rubber pad (bumper) (2) and discard.
10. Remove Connector Position Assurance (CPA) from under the cover.
11. Disconnect the under cover wire harness from the cover, and the fuel pump, noting positions for installation.
12. Support the reservoir with one hand and remove the fuel level sensor assembly (4).

1. Install the fuel level sensor assembly
2. Install the new rubber pad (bumper).
3. Install the external strainer, as noted during disassembly.
4. Install the under cover wire harness, as noted during disassembly.
5. Install the modular fuel sender assembly, refer to Fuel Sender Assembly Replacement .
6. Install the fuel tank, refer to Fuel Tank Replacement .
7. Install the fuel sender electrical connector.
8. Lower the vehicle.
9. Refill the fuel tank.

9.1.	Turn ignition switch to On for 2 seconds.

9.2.	Turn the ignition switch to Off for 5 seconds.

9.3.	Turn the ignition switch On.

9.4.	Check for fuel leaks.