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.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Remove the fuel tank (4). Refer to Fuel Tank Replacement .

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.

5. While holding the modular fuel sender assembly (3) down, remove the snap ring (1) from designated slots located on the retainer (2).

1. Install a new O-ring on the modular fuel sender (3).
2. Install the modular fuel sender to the fuel tank.
3. Align the tab on front of the modular fuel sender (2) with slot on front of the retainer snap ring.
4. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.

Important: Be sure that the snap ring is fully seated within the tab slots.

5. Insert the snap ring (1) into the designated slots.
6. Install the fuel tank. Refer to Fuel Tank Replacement .
7. Lower the vehicle.
8. Refill the fuel tank.
9. Connect the negative battery cable.
10. Inspect for fuel leaks through the following steps:

10.1.

Turn the ignition switch to the ON position for two seconds

10.2.

Turn the ignition switch to the OFF position for ten seconds.

10.3.

Turn the ignition switch to the ON position

10.4.

Check for fuel leaks.