Fuel Sender Assembly Replacement (Prior to VIN 4S558922 (100MM Sender))

FUEL SENDER ASSEMBLY REPLACEMENT (PRIOR TO VIN 4S558922 (100MM SENDER))

TOOLS REQUIRED
J39765-A Fuel Sender Lock Ring Tool

REMOVAL PROCEDURE
1. Remove the fuel tank.




2. Remove the fuel sender shield fasteners.
3. Remove the fuel sender shield.




4. Disconnect the fuel sender electrical connectors.

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.




5. Disconnect the fuel pipes from the fuel sender.

IMPORTANT: The fuel sender assembly will spring up when the fuel sender assembly lock ring is removed.




6. Use the J39765-A (1) in order to remove the fuel sender lock ring.

IMPORTANT: The fuel sender must be tipped in order to remove the sender from the fuel tank. Fuel in the sender reservoir must be placed and stored in an approved container.

7. Remove the fuel sender from the fuel tank.
8. Remove and discard the fuel sender seal.

INSTALLATION PROCEDURE
1. Clean the fuel sender sealing flange.

IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly.

2. Install the NEW fuel sender seal to the fuel tank.

IMPORTANT: Do not 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. Install the fuel sender and the fuel sender lock ring.




4. Use the J39765-A (1) in order to install the fuel sender lock ring.




5. Install the fuel pipes to the fuel sender.




6. Install the fuel sender sensor electrical connectors.




7. Install the fuel sender shield.

NOTE: Refer to Fastener Notice in Service Precautions.

8. Install the fuel sender shield nuts.

Tighten
Tighten the nuts to 6 N.m (53 lb in).

9. Install the fuel tank.