Fuel Sender Assembly Replacement Prior to VIN 4S558922 (100mm Sender)

J39765-A Fuel Sender Lock Ring Tool

1. Remove the fuel tank. Refer to Fuel Tank Replacement .



2. Remove the fuel sender shield fasteners.
3. Remove the fuel sender shield.



4. Disconnect the fuel sender electrical connectors.




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. Disconnect the fuel pipes from the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .




Important: The fuel sender assembly will spring up when the fuel sender assembly lock ring is removed.

6. Use the J39765-A (1) in order to remove the fuel sender lock ring.

Important: The fuel sender must be tipped in order to remove the sender from the fuel tank. Fuel in the sender reservoir must be placed and stored in an approved container.

7. Remove the fuel sender from the fuel tank.
8. Remove and discard the fuel sender seal.

1. Clean the fuel sender sealing flange.

Important: Always replace the fuel sender seal when installing the fuel sender assembly.

2. Install the NEW fuel sender seal to the fuel tank.

Important: Do not fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

3. Install the fuel sender and the fuel sender lock ring.



4. Use the J39765-A (1) in order to install the fuel sender lock ring.



5. Install the fuel pipes to the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .



6. Install the fuel sender sensor electrical connectors.



7. Install the fuel sender shield.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Install the fuel sender shield nuts.

Tighten
Tighten the nuts to 6 N·m (53 lb in).

9. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement VIN 4S558922 and Later (130mm Sender)

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the fuel tank. Refer to Fuel Tank Replacement .



2. Disconnect the fuel sender module electrical connectors.




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.

3. Disconnect the fuel pipes from the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .




Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver are not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

4. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.

Turn the lock ring in a counterclockwise direction.




5. Remove the fuel sender lock ring (1) and the fuel sender (2) from the fuel tank.
6. Remove and discard the fuel sender seal (3).
7. Remove the fuel level sensor from the fuel sender module. Refer to Fuel Level Sensor Replacement .




Important: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.

Important: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

Important: Check the lock ring for flatness.

8. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
9. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
10. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install the fuel level sensor to the fuel sender module. Refer to Fuel Level Sensor Replacement .
2. Clean the fuel sender sealing flange.




Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication to the seal groove.

3. Install the NEW fuel sender seal (3) to the fuel tank seal groove.
4. Install the fuel sender (2) and the fuel sender lock ring (1).



5. Use the J 45722 in order to install the fuel sender lock ring.

Turn the lock ring in a clockwise direction.




6. Install the fuel pipes to the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .



7. Install the fuel sender module electrical connectors.
8. Install the fuel tank. Refer to Fuel Tank Replacement .