Fuel Tank Unit: Service and Repair

WARNING: The water/diesel fuel mixture is flammable, and could be hot. To help avoid personal injury and/or property damage, do not touch the fuel coming from the drain hose, and do not expose the fuel to open flames or sparks. Be sure you do not overfill the container. Heat (such as from the engine) can cause the fuel to expand. If the container is too full, fuel could be forced out of the container. This could lead to a fire and the risk of personal injury and/or vehicle damage.

REMOVAL PROCEDURE
1. Remove the fuel tank filler cap.
2. Disconnect the negative battery cable(s).
3. Raise the vehicle on a hoist.

NOTE: Extreme care must be used when lowering the fuel tank. The fuel sender is made of plastic and may be damaged when lowering the fuel tank.

4. Remove the fuel tank.




5. Use tool J366O8 in order to remove the sender unit by turning the cam lock counterclockwise.

NOTE: Do not damage the rubber insulator or the strainer.




6. Remove the sending unit by pulling up.
7. Inspect the attaching hose for signs of deterioration.
8. Inspect the rubber sound insulation at the bottom of the pump.
9. Inspect the strainer.

INSTALLATION PROCEDURE
1. Install the sender assembly into the attaching hose.

NOTE: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

2. Install the sending unit assembly into the fuel tank.
3. Insert a new O-ring seal.
4. Install the cam lock assembly.
5. Turn the cam lock clockwise in order to lock it.
6. Install the fuel tank.
7. Connect the negative battery cable.
8. Check the system for leaks.
8.1. Turn ON the ignition switch for 2 seconds. The scan tool can be used to activate the fuel pump to check for fuel system leaks.
8.2. Turn OFF the ignition switch for 10 seconds.
8.3. Again, turn the ignition switch to the ON position.
8.4. Check for fuel leaks.