Fuel Sender Assembly Replacement 15 Gallon
Tools Required
J 45722 Fuel Sender Lock
Ring Wrench
Removal Procedure
- Remove the fuel tank. Refer to
Fuel Tank Replacement
.
- Disconnect the fuel lines from the sending unit. Refer to
Metal Collar Quick Connect Fitting Service
or
Plastic Collar Quick Connect Fitting Service
.
- Using J 45722
, remove
the sending unit lock ring.
- Remove the sending unit and seal. Discard
the seal.
- Clean the sending unit sealing surfaces.
Installation Procedure
- Install the sending unit and a NEW seal.
- Using the J 45722
, install the sending unit lock ring.
- Connect the fuel lines to the sending unit. Refer to
Metal Collar Quick Connect Fitting Service
or to
Plastic Collar Quick Connect Fitting Service
.
- Install the fuel tank. Refer to
Fuel Tank Replacement
.
Fuel Sender Assembly Replacement Rear Tank
Removal Procedure
- Remove the fuel tank. Refer to
Fuel Tank Replacement
.
- Remove the 6 nuts and washers from the fuel sender assembly retaining ring .
- Remove the fuel sender assembly retaining ring.
- Remove the fuel sender assembly.
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.
- Remove the fuel sender assembly seal from the fuel tank.
Installation Procedure
- Install the fuel sender assembly seal to the fuel tank.
Notice: Do not fold or twist the strainer when installing the sending unit.
This action restricts fuel flow.
- Care should be taken not to fold over or twist the strainer when installing the sender assembly as this will restrict fuel flow.
- Install the fuel sender assembly in the fuel tank.
- Install the fuel sender assembly lock ring to the fuel tank, make sure the lock ring alignment holes fit over the tabs on the tank.
Notice: Refer to Fastener Notice in the Preface section.
- Install the 6 washers and nuts retaining the fuel sender assembly lock ring.
Tighten
Tighten the lock ring nuts to 11.5 N·m (102 lb in).
- Install the fuel tank. Refer to
Fuel Tank Replacement
.
Fuel Sender Assembly Replacement Mid Mount Tank
Tools Required
J 44402 Fuel Tank Sending Unit Wrench
Removal Procedure
- 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.
- Remove the fuel sender assembly retaining ring using
the J 44402
.
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.
- Remove the fuel sender assembly and the seal. Discard
the seal.
- Clean the fuel sender sealing surfaces.
Installation Procedure
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.
Important: The fuel 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 strainer does not block full travel of the float arm.
- Install the new seal on the fuel tank.
- Install the fuel sender assembly into the fuel tank.
- Install the fuel sender assembly retaining ring using
the J 44402
.
- Install the fuel tank. Refer to
Fuel Tank Replacement
.