Caution: In order to Reduce the Risk of Personal Injury: Always allow for proper ventilation when working with fuel in enclosed areas.

Caution: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Drain fuel tank. Refer to Fuel Tank Draining .
3. Remove fuel tank (4). Refer to Fuel Tank Replacement .
4. Remove the locking nut using J 39765 by turning counterclockwise.

Important: 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. Have a shop towel ready to absorb any leakage.

5. Remove modular fuel sender assembly (1) from the fuel tank.
6. Remove fuel sender seal (lip). Slide the fuel sender lip seal downward, past the reservoir and carefully over the float arm assembly
7. Discard the fuel sender lip seal.
8. Carefully discard the reservoir fuel into an approved container.

Important: Lip seal should be carefully positioned over the float arm assembly, moved up over the reservoir and half way up the guide posts.

1. Install new lip seal on modular fuel sender assembly. Always use a new lip seal when servicing modular fuel sender unit.
2. Lightly lubricate the inside diameter of the lip seal with clean engine oil.
3. Install modular fuel sender assembly (1) into the fuel tank. Seat the lip seal into tank opening.
4. Align arrow on top of the fuel sender cover to arrow on the fuel tank.
5. Slowly apply pressure to the top of the spring loaded sender until the lip seal is flush between the fuel tank and the fuel sender cover.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the locking nut using J 39765 by turning clockwise.

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

Tighten
Tighten the locking nut and tighten locking nut to 34 N·m 25 lb ft).

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



8. Lower the vehicle.
9. Add fuel to the fuel tank.
10. Install the fuel tank filler pipe cap.
11. Install the negative battery cable.

11.1.

Turn ignition switch to ON for 2 seconds.

11.2.

Turn the ignition switch to OFF for 5 seconds.

11.3.

Turn the ignition switch ON.

11.4.

Check for fuel leaks.




12. Install the intake manifold top cover.

Tighten
Tighten the nuts to 3 N·m (27 lb in).