Tools Required

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Remove the fuel tank. Refer to Fuel Tank 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.

5. Remove the fuel sender assembly retaining ring using the J 39765 fuel sender lock nut wrench.

Caution: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.

6. Remove the fuel sender assembly and the seal. Discard the seal.
7. Clean the fuel sender sealing surfaces.

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. Install the new seal on the fuel tank.

Important: The fuel pump strainer must be in a horizontal position when the fuel sender is installed 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 into the fuel tank.
3. Install the fuel sender assembly retaining ring using the J 39765 Fuel Sender Lock Nut Wrench.
4. Install the fuel tank. Refer to Fuel Tank Replacement .
5. Refill the fuel tank.
6. Tighten the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks.

8.1.	Turn ON the ignition for 2 seconds.

8.2.	Turn OFF the ignition for 10 seconds.

8.3.	Turn ON the ignition.

8.4.	Inspect for fuel leaks.