Service Procedure

To replace fuel meter the following procedure may be used:

1. Relieve fuel pressure from system following the proper procedure.

2. Remove negative battery cable.

3. Drain fuel from fuel tank.

Have a dry chemical (Class B) fire extinguisher nearby.

CAUTION:
NEVER DRAIN OR STORE GASOLINE OR DIESEL FUEL IN AN OPEN CONTAINER, DUE TO THE POSSIBILITY OF FIRE OR EXPLOSION.


4. Use a hand operated pump device to drain as much fuel as possible through the filler neck. On some fuel tank installations, the filler neck is too long to gain access to the fuel. If the tank is not full, disconnect filler neck nose, at the fuel tank, to gain access to the fuel.

Alternate method:

a. Disconnect fuel feed pipe and attach a hand operated pump device.

b. Energize the fuel pump relay.

c. With fuel pump running, operate hand pump to remove fuel.

5. Raise vehicle on hoist.

6. Disconnect propeller shaft, move out of the way and secure.

7. Remove clamps from filler neck hose and vent line. Figure 4-45 in X-9129 S/T Truck Service Manual, page 4-31.

8. Remove fuel tank retaining straps. Figure 4-47 in X-9129 S/T Truck Service Manual, page 4-31.
Support the fuel tank.

9. Remove sender unit wires, hoses, and ground strap.
Lower the fuel tank to gain access.

10. Remove fuel tank from the vehicle.

11. Remove sender unit and pump by turning the cam lock counter-clockwise using tool J 36608 or J 24187. Figure 4-34 in X-9129 S/T Truck Service Manual, page 4-31.

12. Disconnect electrical terminals from pump;

13. Remove clamps from rubber coupler.

NOTE:
MARK POSITION OF STRAINER ON PUMP; remove strainer by rotating in one direction while pulling off and discard.

14. Pull the fuel pump up into the attaching hose while pulling outward from the bottom support.

Do not damage rubber isolator.


15. Install fuel pump assembly into the attaching hose.

NOTE:
The fuel pump cannot be run dry because bearing damage can result in as little as 15 seconds. Also, care must be taken not to fold over or twist the strainer, when installing the sending unit as this will restrict fuel flow.

Use the new strainer and align to original position.

16. Seat rubber isolator and pump securely in mounting bracket.
Tighten both clamps securely.

17. Install sending unit and fuel pump assembly into the fuel tank.

- Use the new O-ring seal.

18. Reinstall fuel tank as per specifications in Figure 4-47 in
X-9129 S/T Truck Service Manual, page 4-31, and reconnect hoses and electrical connectors.

19. Connect propshaft, torque to 29 N-m (15 lbs.ft.).

20. Lower vehicle.

21. Connect negative battery cable.

22. Check old fuel for contamination before refilling fuel tank.

23. Start vehicle and inspect all connections for leaks.

24. Install "Campaign Identification Label".