Fuel Tank Unit: Service and Repair

REMOVAL PROCEDURE

Tools Required
^ J 34730-1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Remove the fuel tank. Fuel Tank Replacement
5. Fuel Tank Replacement (Passenger/Cargo Van) or Fuel Tank Replacement (Cutaway Van Rear Tank) or Fuel Tank Replacement (Cutaway Van Side Tank)

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.

6. Remove the retaining ring from the fuel sender assembly using the J 39765 fuel sender lock nut wrench.
7. Remove the fuel sender assembly and the seal. Discard the seal.

CAUTION: Drain the fuel from the fuel sender assembly into an approved container In order to reduce the risk of fire and personal injury. Never store the fuel in an open container.

8. Clean the fuel sender sealing surfaces.

INSTALLATION PROCEDURE

CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Install the new seal on the fuel tank.

IMPORTANT: The fuel strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel strainer does not block full travel of the float arm.

2. Install the fuel sender assembly into the fuel tank.

NOTE: Refer to the Fastener Notice in Service Precautions.

3. Install the retaining ring to the fuel sender assembly using the J 39765 fuel sender lock nut wrench.

4. Remove the fuel tank.

6. Refill the fuel tank.
7. Tighten the fuel filler cap.
8. Connect the negative battery cable.
9. Inspect for leaks:
9.1. Turn the ignition switch ON for 2 seconds.
9.2. Turn the ignition switch OFF for 10 seconds.
9.3. Turn the ignition switch ON.
9.4. Inspect for fuel leaks.