Fuel Sender Assembly Replacement for Generic Unit Repair 1999

Tools Required

Fuel Sender Lock Nut Wrench

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure by removing the fuel filler cap.
3. Drain the fuel tank. Refer to
4. Remove the fuel tank. Refer to

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 Fuel Sender Lock Nut Wrench.
6. Remove the fuel sender assembly and the seal. Discard the seal.

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.

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 Fuel Sender Lock Nut Wrench.



4. Install the fuel tank. Refer to
5. Refill the fuel tank.
6. Install the fuel filler cap.
7. Connect the negative battery cable.
8. Using the scan tool, activate fuel lift pump and inspect for leaks.