Fuel Tank Unit: Service and Repair

REMOVAL PROCEDURE

TOOL REQUIRED
J 39348 Fuel Sender Spanner Wrench

NOTE: 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.

IMPORTANT: Always replace the fuel sender gasket when Installing the fuel sender assembly.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Service Precautions.
4. Remove the fuel tank.
5. 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.
6. Disconnect the quick-connect fittings at the fuel sender assembly.
7. Use the J 39348 fuel sender spanner wrench in order to remove the fuel sender assembly locking nut, the fuel sender assembly and the O-ring from the fuel tank.
8. Discard the fuel sender assembly O-ring.

INSTALLATION PROCEDURE
1. Clean the fuel sender assembly O-ring sealing surfaces.
2. Position the new fuel sender assembly O-ring on the 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.

3. Use the J 39348 fuel sender wrench in order to install the fuel sender assembly and the fuel sender assembly locking nut.
4. Connect the quick-connect fittings at the fuel sender assembly.
5. Install the fuel tank.
6. Lower the vehicle.
7. Add fuel and Install the fuel fill cap.
8. Connect the negative battery cable.
9. Inspect for fuel leaks using the following procedure:
9.1. Turn ON the ignition, for 2 seconds.
9.2. Turn OFF the ignition, for 10 seconds.
9.3. Turn ON the ignition.
9.4. Inspect for fuel leaks.