Fuel Sender Assembly Replacement

CAUTION: Place a dry chemical (Class B) fire extinguisher near work area before attempting any On-Vehicle Service.

TOOLS REQUIRED
J 42219 Fuel Tank Sender Wrench

REMOVAL
1. Perform the Fuel Pressure Release procedure.
2. Drain the fuel tank.
3. Remove the fuel tank.
4. Remove the spring loaded clamp around the fuel tank boot.
5. Remove the fuel tank sending unit wiring harness.

Notice: The modular fuel sender assembly may spring up from its position. When removing the modular assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. Tip the modular assembly slightly during removal to avoid damage to the float. Use a shop towel to absorb any leakage.

6. Remove the fuel sender assembly from the fuel tank by using the J42219.
7. Remove the fuel sender seal (lip) from the fuel sending unit cover. Slide the fuel sender seal downward, past the reservoir and carefully over the float arm assembly.
8. Discard the fuel sender lip seal. Carefully discard the reservoir fuel into an approved container.

INSTALLATION

Important: Always replace the fuel sender assembly lip seal when reinstalling the fuel sender assembly.

1. Install a new lip seal on modular fuel sender assembly.
^ Lightly lubricate the inside diameter of the lip seal with engine oil.
^ Position the lip seal over the float arm assembly.
^ Move the lip seal up over the reservoir and onto the fuel sending unit cover.
2. Install the modular fuel sender assembly into the tank.
3. Seat the lip seal into the tank opening.
4. Align a hole on the edge of the fuel sender cover in order to mark on the fuel tank.
5. Use the J 42219 in order to attach the locking nut.
^ Be sure that the lip seal provides a snug seal between the fuel sending unit and the fuel tank.

Tighten nut to 50 Nm (37 lb ft).

6. Install the fuel tank.