Fuel Sender Assembly Replacement 1st design

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

•	Refer to Fuel Tank Replacement (Passenger/Cargo Van) for the Passenger/Cargo Van.

•	Refer to Fuel Tank Replacement (Commercial/RV Cutaway) for the Commercial/RV Cutaway Van.

1. Note the position of the fuel pump strainer on the fuel pump.
2. Support the pump with one hand and grasp the strainer with the other hand.
3. Rotate the strainer in one direction and pull off the pump. Discard the strainer after inspection.
4. Inspect the fuel pump strainer. Replace the strainer if it has contaminates and clean the fuel tank.
5. Inspect the fuel pump inlet for dirt and debris. If found, replace the pump.

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Push on the outer edge of the ferrule until fully seated.
2. Support the pump with one hand and position the new pump strainer on pump in the same position as noted during disassembly.

1. Install a new seal, sending assembly and lock ring. Make sure the lock ring alignment holes fit over the tabs on the tank.
2. Install the cam lock assembly. Turn the cam lock clockwise to lock it.
3. Install the fuel tank.

•	Refer to Fuel Tank Replacement (Passenger/Cargo Van) for the Passenger/Cargo Van.

•	Refer to Fuel Tank Replacement (Commercial/RV Cutaway) for the Commercial/Cutaway Van.

4. Add fuel removed from the tank.
5. Connect the negative battery cable.
6. Check for fuel leaks.

6.1.	Turn the ignition ON for 2 seconds.

6.2.	Turn OFF the ignition for 10 seconds.

6.3.	Again, turn the ignition switch to the ON position.

6.4.	Check for fuel leaks.

Fuel Sender Assembly Replacement 2nd design

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

•	Refer to Fuel Tank Replacement (Passenger/Cargo Van) for the Passenger/Cargo Van.

•	Refer to Fuel Tank Replacement (Commercial/RV Cutaway) for the Commercial/RV Cutaway Van.




5. Remove the sender assembly by turning the cam lock counterclockwise using tool J36608 .

1. Note the position of the fuel pump strainer on the fuel pump.
2. Support the pump with one hand and grasp the strainer with the other hand.
3. Rotate the strainer in one direction and pull off the pump. Discard the strainer after inspection.
4. Inspect the fuel pump strainer. Replace the strainer if it has contaminates and clean the fuel tank.
5. Inspect the fuel pump inlet for dirt and debris. If found, replace the pump.

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Push on the outer edge of the ferrule until fully seated.
2. Support the pump with one hand and position the new pump strainer on pump in the same position as noted during disassembly.

1. Install a new seal, sending assembly and lock ring. Make sure the lock ring alignment holes fit over the tabs on the tank.
2. Install the cam lock assembly. Turn the cam lock clockwise to lock it.
3. Install the fuel tank.

•	Refer to Fuel Tank Replacement (Passenger/Cargo Van) for the Passenger/Cargo Van.

•	Refer to Fuel Tank Replacement (Commercial/RV Cutaway) for the Commercial/Cutaway Van.

4. Add fuel removed from the tank.
5. Connect the negative battery cable.
6. Check for fuel leaks.

6.1.	Turn the ignition ON for 2 seconds.

6.2.	Turn OFF the ignition for 10 seconds.

6.3.	Again, turn the ignition switch to the ON position.

6.4.	Check for fuel leaks.