Removal Procedure
- Disconnect the negative battery cable.
- Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH-48027) , Fuel Pressure Relief (CH-48027) .
- Drain the fuel tank. Refer to Fuel Tank Draining (L59) , Fuel Tank Draining (Without L59) .
- Remove the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Rear Tank) , Fuel Tank Replacement (Cutaway Van Side Tank) , Fuel Tank Replacement (Passenger/Cargo) .
- Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
- Remove the fuel sender assembly and the seal. Discard the seal.
- Clean the fuel sender sealing surfaces.
- Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.
- Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
- Check the lock ring for flatness.
- Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
- If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
- If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
WARNING:
Refer to Battery Disconnect Warning .
CAUTION:
Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
CAUTION:
Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
NOTE:
Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
WARNING:
Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container
NOTE: