Removal 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.
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to
the vehicle or its components.
- Disconnect the negative battery cable.
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief
.
- Remove the pickup box. Refer to
Pickup Box Replacement
in Body
Rear End.
- Disconnect the fuel sender electrical connectors.
- Disconnect the fuel sender fuel and evaporative emission (EVAP)
pipes.
Important:
| • | The modular fuel sender assembly may spring up from the fuel tank. |
| • | When removing the modular fuel sender assembly from the fuel tank,
be aware that the reservoir bucket is full of fuel. The fuel sender assembly
must be tipped slightly during removal to avoid damage to the
float. Discard fuel sender O-ring and replace with a new one. |
| • | Carefully discard the reservoir fuel into an approved container. |
- While holding the modular fuel sender assembly down, remove the snap
ring from designated slots (1) located on the retainer.
Installation Procedure
- Install a new O-ring on the modular fuel
sender to the tank.
- Align the tab on front of the modular sender with slot on front
of the retainer snap ring.
- Slowly apply pressure to top of the spring loaded sender until
the sender aligns flush with retainer on the tank.
Important: Ensure that the snap ring is fully seated within the tab slots.
- Insert snap ring into designated slots (1).
- Connect the fuel sender fuel and EVAP pipes.
- Connect the fuel sender electrical connectors.
- Connect the negative battery cable.
- Inspect for fuel leaks through the following steps:
| 8.1. | Turn ON the ignition for 2 seconds. |
| 8.2. | Turn OFF the ignition for 10 seconds. |
| 8.3. | Turn ON the ignition. |
| 8.4. | Inspect for fuel leaks. |
- Install the pickup box. Refer to
Pickup Box Replacement
in
Body Rear End.
