Fuel Tank Unit: Service and Repair

Fuel Sender Assembly Replacement

Tools Required

J 45722 Fuel Tank Sending Unit Wrench

Removal Procedure

1. Remove the fuel tank. Refer to Fuel Tank Replacement (Removal and Replacement).





Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

Notice: 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: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.


2. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.




3. Remove the fuel sender assembly (2) and the seal (3). 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.

4. Clean the fuel sender sealing surfaces (4).





Important:
* Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.

* Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

* Check the lock ring for flatness.


5. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
6. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
7. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

Installation Procedure




1. Install the new seal (3) on the fuel tank.
Important: The fuel pump 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 pump strainer does not block full travel of the float arm.


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





Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.


Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.


3. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
4. Install the fuel tank. Refer to Fuel Tank Replacement (Removal and Replacement).