Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Tools required

J 42219-B Fuel Tank Sender Wrench

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief ).
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the fuel tank. Refer to Fuel Tank Replacement .
4. Remove the spring loaded clamp around the fuel tank boot.
5. Remove the fuel tank sending unit wiring harness

Notice: The modular fuel sender assembly may spring up from its position. When removing the modular assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. Tip the modular assembly slightly during removal to avoid damage to the float. Use a shop towel to absorb any leakage.

6. Remove the fuel sender assembly from the fuel tank by using the J 42219-B .
7. Remove the fuel sender seal (lip) from the fuel sending unit cover. Slide the fuel sender seal downward, past the reservoir and carefully over the float arm assembly.
8. Discard the fuel sender lip seal. Carefully discard the reservoir fuel into an approved container.

Important: Always replace the fuel sender assembly lip seal when reinstalling the fuel sender assembly.

1. Install a new lip seal on modular fuel sender assembly.

•	Lightly lubricate the inside diameter of the lip seal with engine oil.

•	Position the lip seal over the float arm assembly.

•	Move the lip seal up over the reservoir and onto the fuel sending unit cover.

2. Install the modular fuel sender assembly into the tank.
3. Seat the lip seal into the tank opening.
4. Align a hole on the edge of the fuel sender cover in order to mark on the fuel tank.
5. Use the J 42219-B in order to attach the locking nut and tighten the locking nut to 50 N·m (37 lb ft).

Be sure that the lip seal provides a snug seal between the fuel sending unit and the fuel tank.

6. Install the fuel tank. Refer to Fuel Tank Replacement .