Fuel Sender Assembly Replacement Utility

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.

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 fuel tank. Refer to Fuel Tank Draining .
4. Remove the fuel tank. Refer to Fuel Tank Replacement .




Important: 

•	The modular fuel sender assembly may spring up from its position.

•	When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one.

•	Carefully discard the reservoir fuel into an approved container.

5. While holding the modular fuel sender assembly down, remove the snap ring from designated slots (1) located on the retainer.

1. Install a new O-ring on the modular fuel sender to the tank.
2. Align the tab on front of the modular sender with slot on front of the retainer snap ring.
3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.

Important: Be sure that the snap ring is fully seated within the tab slots.

4. Insert snap ring into designated slots (1).
5. Install the fuel tank. Refer to Fuel Tank Replacement .

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

6. Lower the vehicle.
7. Refill the fuel tank.

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.

8. Connect the negative battery cable.
9. Inspect for fuel leaks through the following steps:

9.1.	Turn the ignition to the ON position for 2 seconds.

9.2.	Turn the ignition to the OFF position for 10 seconds.

9.3.	Turn the ignition to the ON position

9.4.	Check for fuel leaks.