B. Tank and Gasket Replacement
1. Drain any remaining fuel from the fuel tank into an approved container.2. Disconnect the fuel line that runs between the fuel pump and the gauge unit (Figure 3).
3. Remove and discard the fuel pump and gauge unit retaining caps using Miller special tool 6856.
4. Carefully remove the fuel pump assembly.
NOTE:
The fuel pump assembly also contains a gauge unit. Be careful not to rotate or excessively tilt the fuel pump assembly to prevent damage to either the filter or the float arm.
5. Remove the gauge unit.
NOTE:
Be careful not to rotate or excessively tilt the gauge unit to prevent damage to either the filter or the float arm.
6. Remove and discard the fuel pump and gauge unit gaskets.
7. Install one of the supplied gaskets into the fuel pump opening of the supplied fuel tank.
NOTE:
Ensure that the gasket is properly positioned in the opening. The gasket should be fully seated on the tank neck, the ribs on the outside diameter of the gasket must not be deformed and the top flange of the gasket must be flush with the outside diameter of the tank neck (Figure 4).
8. Coat the inside diameter of the gasket with the provided lubricant.
9. Align the mark molded into the top of the fuel tank with the 2 stamped marks on the top of the fuel pump (Figure 5).
10. Carefully insert the fuel pump into the opening while keeping the marks aligned.
CAUTION:
The pump must not be allowed to rotate during installation. If the pump rotates before or during the torque procedure, the float arm may contact the internal reservoir or the inside of the fuel tank and cause inaccurate fuel gauge readings.
11. Inspect the gasket to make sure it did not get rolled into the tank opening. Make sure that the gasket outer circumference is flush with the outside diameter of the fuel pump flange (Figure 4).
NOTE:
If the gasket is not flush, make sure the gasket is not damaged, then reposition and relubricate the gasket.
12. Loosely install one of the provided retaining rings.
13. Repeat Steps 7-12, to install the gauge unit into the other tank opening.
14. Tighten the two retaining rings to 52 ft-lbs (70 N.m) using the special tool (6856). Make sure that the pump assembly and gauge unit do not rotate while the retaining cap is being tightened.
15. Transfer the rollover valve from the original fuel tank to the new fuel tank. Tighten the nuts to 22 in-lbs (2.5 N.m) (Figure 3).
16. Transfer the fuel filler hose from the original fuel tank to the new fuel tank. Secure the hose using the larger (52 mm) supplied clamp.
17. Transfer the fuel line that connects the gauge unit to the fuel pump unit from the old fuel tank to the new fuel tank. Connect the fuel line to the gauge unit and the fuel pump.
18. Connect the gauge unit wiring connector. Secure the wiring harness and fuel line to the fuel tank with the supplied adhesive pad.
19. Route the rollover valve fuel vapor hose in the tank channel. Secure it in place using the provided self-stick pad (Figure 6).
20. Verify the operation of the gauge units as follows:
A. Connect an ohmmeter to the fuel pump electrical connector as shown in Figure 7.
B. With the tank in the normal position, the float should be fully down and the ohmmeter should read 56.9 +/-1 ohms.
C. Gently roll the fuel tank over. The ohmmeter reading should smoothly drop until it reads 2 +/-1 ohms in the full position.
D. Disconnect the ohmmeter from the fuel pump and attach it to the gauge unit electrical connector as shown in Figure 8.
E. With the tank still upside down and the float in the full position, the ohmmeter should read 2 +/-1 ohms.
F. Gently return the tank to the normal position. The ohmmeter should read 50.1 +/-1 ohms. C
G. If any of the readings are outside of the specifications, the float is contacting the inside of the fuel tank. Loosen the retaining ring on the affected unit and carefully rotate the gauge unit and/or fuel pump until the alignment marks are properly aligned (Figure 5). Then retighten the retaining ring to 52 ft-lbs (70 N.m) using the special tool (6856).