WARNING: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN.

This pressure must be relieved before servicing the fuel system. A valve is provided on the fuel rail assembly for this purpose. Attach EFI and CFI Fuel Pressure Gauge T80L-9974-B to fuel diagnostic valve on fuel rail assembly. Pressure in fuel system may now be released.

Fuel Sender Unit

Tools Required:

• EFI and CFI Fuel Pressure Gauge T80L-9974-B
• Fuel Tank Sender Wrench D84P-9275-A
• Rotunda Fuel Storage Tanker 034-00002
• Rotunda Fuel Storage Tanker Adapter Hose 034-00012

Removal

1. Place vehicle on hoist. Do not raise.

2. Depressurize fuel system as outlined.

3. Remove the fuel from the fuel tank using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00012 or equivalent.

4. Raise vehicle on hoist. Refer to Section 00-02.

5. Support fuel tank and remove fuel filler tube and fuel tank retaining straps. Lower fuel tank. Remove fuel lines, vent hose and electrical connector.

6. Move fuel tank to workbench.

7. Remove any dirt that has accumulated around the sender unit so that it will not enter the tank or connections.

8. Turn the sender unit locking ring counterclockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent and remove the locking ring, sender unit and seal ring. Discard seal ring.

Installation

1. Clean the fuel gauge sender unit mounting surface at the fuel tank.

2. Apply a light coating of Premium Long-Life Grease XG-1-C (ESA-M1C75-B) or equivalent on new seal ring, and install in ring groove.

3. Install fuel sender. Ensure locating keys align in keyways and seal remains in groove.

4. Install retaining ring. Hold sender unit in position and turn retaining ring against stops using Fuel Tank Sender Wrench D84P-9275-A or equivalent.

5. Install fuel tank in vehicle. Connect fuel lines, vent hose and electrical connector.

6. Secure fuel tank with retaining straps.

7. Lower vehicle. Install filler tube. Add a minimum of 38L (10 gal) of fuel.

8. With EFI and CFI Fuel Pressure Gauge T80L-9974-B installed, turn ignition switch from the Off position to the On position for three second intervals until fuel pressure builds to 241 kPa (35 psi).

9. Start engine and check for fuel leaks.
   
   
   
   
   

   Item	Part Number	Description
   1	9C385	Locking Ring
   2	9276	Gasket
   3	—	Tab
   4	—	Stop
   5	—	Detent