Fuel Tank Unit: Service and Repair

REMOVE OR DISCONNECT

CAUTION: Do Not handle the fuel sender assembly by the fuel pipes. Due to the length of the fuel pipes, the amount of leverage generated by handling the fuel pipes could damage the joints.


NOTE: In order to avoid damage to the fuel sender assembly, always replace the fuel sender O-Rings when re-installing the fuel sender assembly.


1. Relieve the fuel system fuel pressure, refer to the Fuel Pressure Relief Procedure.
2. Drain the fuel tank, refer to Draming Fuel Tank.
3. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
4. Remove the the fuel tank.
5. Remove the quick-connect fittings at the fuel sender assembly (1) refer to Servicing Quick Connect Fittings.

DISASSEMBLE PROCEDURE
1. Remove the fuel sender assembly retaining cam (1), using the J 35731 Fuel Sender Spanner Wrench or equivalent.
2. Remove the fuel sender assembly and the O-Ring from the fuel tank.
3. Discard the fuel sender assembly O-Ring.
4. Clean the fuel sender assembly O-Ring sealing surfaces.
5. Inspect the fuel sender assembly O-Ring sealing surfaces.

ASSEMBLE PROCEDURE

NOTE: Care should be taken not to 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.

1. Position the new fuel sender assembly O-Ring on the fuel tank.
2. Assemble the fuel sender assembly and the fuel sender assembly retainer cam using the J 35731 Fuel Sender Spanner Wrench or equivalent.

INSTALL OR CONNECT
1. Install the fuel tank, refer to Fuel Tank.
2. Lower the vehicle.
3. Add fuel and install the fuel tank filler pipe cap.
4. Install the negative battery cable.
5. Inspect for leaks.
- Turn the ignition switch to the On position for 2 seconds.
- Turn the ignition switch to the 0ff for ten seconds.
- Turn the ignition switch to the On position.
- Check for fuel leaks.


LEGEND
1. Fuel Sender Assembly
2. Fuel Level Sensor Assembly
3. Filter
4. Fuel Pummp