Fuel Tank Unit: Service and Repair

REMOVAL PROCEDURE

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.

NOTE:
^ 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.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

IMPORTANT: Always maintain cleanliness when servicing fuel system components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. Service and Repair
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. Procedures
4. Remove the fuel tank.
5. Remove the fuel sender assembly retaining nuts (1), the retaining ring (2), the fuel sender assembly (3), and the gasket (4). Discard the gasket.

CAUTION: 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.

6. Clean the gasket sealing surfaces.

INSTALLATION PROCEDURE

1. Position the new gasket on the fuel tank.

IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

2. Carefully fold the strainer to allow it to fit through the opening in the fuel tank. Make sure the strainer unfolds once it is placed in the tank.
3. Install the fuel sender assembly into the fuel tank.
4. Install the fuel sender retaining ring (2).

NOTE: Refer to Fastener Notice in Service Precautions.

5. Reinstall the fuel sender assembly retaining nuts (1).

Tighten
Tighten the fuel sender assembly retaining nuts alternately and evenly to 6.5 N.m (58 lb in).

6. Reinstall the fuel tank.
7. Add fuel.
8. Reinstall the fuel tiller cap.
9. Connect the negative battery cable.
10. Inspect for leaks.
10.1. Turn ON the ignition for 2 seconds.
10.2. Turn OFF the ignition for 10 seconds.
10.3. Turn ON the ignition.
10.4. Check for fuel leaks.