Removal/Installation

Fuel Sender Assembly Removal:

Important: Always replace fuel sender O-ring when reinstalling fuel sender assembly.

Tool Required: J 35731 Fuel Tank Sending Unit Spanner Wrench or equivalent.

Removal

1. Negative battery cable.
2. Relieve fuel system pressure (see "Fuel System Pressure Relief").
3. Drain and remove fuel tank (see "Fuel Tank Replacement").

Disassembly

1. Fuel sender electrical connector from fuel tank routing clips (2).
2. Fuel tank vapor pipe and clamp.

NOTICE:
^ If nylon fuel feed or return pipes becomes kinked, and cannot be straightened, they must be replaced.
^ Do Not attempt to repair sections of nylon fuel pipes. If damaged, replace.

3. Fuel feed and return pipe quick-connect fittings at fuel sender (see "Servicing Quick-Connect Fittings.")
4. Using J 35731 remove fuel sender assembly retaining cam, fuel sender assembly and 0-ring from fuel tank. Discard 0-ring

Assembly

1. Position new 0-ring on fuel tank.

Important: 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.

2. Install fuel sender assembly and fuel sender assembly retainer cam using J 35731.
3. Install fuel feed and return quick-connect fittings at fuel sender assembly (see "Servicing Quick-Connect Fittings").
4. Install fuel tank vapor pipe and clamp.
5. Assemble fuel sender electrical connector on fuel tank routing clips (2).

Installation

1. Install fuel tank (see "Fuel Tank Replacement").
2. Add fuel and install fuel filler cap.
3. Reconnect negative battery cable.

Inspection

Turn ignition switch to "ON," position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.