Fuel Gauge Sender: Service and Repair

Special tools, testers and auxiliary items
- 3217 Collar wrench


Removing:
- Observe safety precautions.
- Switch off ignition.
- Disconnect battery ground strap.

CAUTION: Obtain Anti-theft radio code before disconnecting battery ground strap.

Remove Driver's Seat.
- Lift carpeting above the hand brake lever.
- Remove cover plate.




Disconnect 4-pin harness connector from flange.
- Disconnect supply and return lines from flange.

CAUTION: Fuel system is under pressure! Before opening the system, place a rag around the connection and release the pressure by slowly loosening the connection.




Remove collar nut using tool 3217.
- Pull flange and seal out of opening in fuel tank.
- Release delivery unit by turning to the left and then out of the bayonet connection.
- Remove the delivery unit.

CAUTION: If the delivery unit contains any fuel, empty it before replacing.

Installing:

NOTE: Fuel delivery unit installation is performed in the reverse order of the removal procedure.

Installation Notes:
- When inserting the fuel delivery unit ensure that the fuel gauge sender is not bent.
- Coat flange seal with fuel when installing.
- Ensure that fuel lines are correctly located and properly tightened.




Note installed position of fuel delivery unit flange: Marking on flange must align with marking on fuel tank.
- Do not interchange the supply and return lines (return line is -blue-).




When the fuel delivery unit is correctly installed:
Fuel gauge sender float points in direction of travel A: alpha= 25 to 35°.