Fuel Sender Assembly Replacement

Fuel Sender Replacement:

TOOLS REQUIRED
J 24187 (-A) / J 36608 fuel sender spanner tool, or equivalent.

CAUTION:
- Do Not handle the fuel sender by the fuel pipes. Due to the length of the pipes, the amount of leverage generated by handling the pipes could damage the solder joints.
- Always replace fuel sender O-Rings when reinstalling fuel sender assembly.

REMOVE OR DISCONNECT
1. Relieve fuel system pressure. Refer to Fuel System / Service and Repair. Service and Repair
2. Drain fuel tank.
3. Fuel tank.

DISASSEMBLE
- Using J 35731, remove fuel sender assembly retaining cam, fuel sender assembly and O-Ring from fuel tank. Discard fuel sender assembly O-Ring.

CLEAN AND INSPECT
Fuel sender assembly O-Ring sealing surfaces.

ASSEMBLE
1. Position new fuel sender assembly O-Ring on fuel tank.

CAUTION: 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. Fuel sender assembly and fuel sender assembly retainer cam using J 35731.
3. Chassis to sender fuel feed and return pipe assemblies to fuel sender quick-connect fittings.

INSTALL OR CONNECT
1. Fuel tank.
2. Add fuel and install fuel filler cap.

INSPECT
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