1. J 34730-1A Fuel Pressure Gauge
2. J 39765 Fuel Sender Locknut Wrench

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. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in general information.
4. Remove fuel tank (4). Refer to Fuel Tank Replacement .
5. Remove the locking nut using J 39765 Fuel Sender Locknut Wrench.

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.

6. Remove modular fuel sender assembly (1) from the fuel tank.
7. Remove fuel sender seal (lip). Slide the fuel sender lip seal downward, past the reservoir and carefully over the float arm assembly
8. Discard the fuel sender lip seal.
9. 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.

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

6. Install the locking nut using J 39765 Fuel Sender Locknut Wrench.
7. Install the fuel tank. Refer to Fuel Tank Replacement .



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

    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.

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12. Inspect for fuel leaks.

12.1.

Turn ignition switch ON for 2 seconds.

12.2.

Turn the ignition switch OFF for 10 seconds.

12.3.

Turn the ignition switch ON.

12.4.

Check for fuel leaks.

13. Reinstall the intake manifold sight shield. Refer to Intake Manifold Removal in engine mechanical.