INSTRUMENTS
88-6 REPAIRS
Sender unit - fuel tank gauge
$% 88.25.32
Remove
1.Disconnect battery earth lead.
2.Remove fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Pump - integral - fuel tank - rear -
up to 03MY.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
3.Disconnect 2 Lucars from top of pump unit
assembly.
4.Release sprag clip securing sender to pump
unit assembly.
5.Remove sender unit.
Refit
1.Position sender to location slots and engage
sprag clip.
CAUTION: Ensure that each of the 4
location lugs on the sender are engaged
with corresponding slots in the tank unit.
2.Connect Lucars to top of pump unit assembly.
3.Fit fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Pump - integral - fuel tank - rear -
up to 03MY.
4.Connect battery earth lead.
Sender unit assembly - fuel tank - Td4
models - from 03MY
$% 88.25.37
Remove
1.Disconnect battery earth lead.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
2.If fuel tank is full, using a fuel recovery
appliance, drain excess fuel from fuel filler neck
until a level below height of fuel pump is
obtained.
3.Open RH rear and tail doors.
4.Fold RH rear seat forward.
5.Remove 3 fasteners securing front and rear
carpets.
6.Pull back carpet from fuel tank sender
assembly access panel.
M88 0356
INSTRUMENTS
REPAIRS 88-7
7.Remove 6 screws securing fuel tank sender
assembly access panel to floor.
8.Remove fuel tank sender assembly access
panel.
9.Disconnect multiplug from fuel tank sender
assembly.
10.Place a container beneath fuel tank to collect
possible fuel spillage.
11.Release and remove fuel pressure relief, fuel
feed and return hoses from fuel tank sender
assembly.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
12. Models with fuel burning heater (FBH):
Release clip and disconnect FBH fuel feed
hose from fuel tank sender assembly.
CAUTION: Always fit plugs to open
connections to prevent contamination.13.Use LRT-19-009 and remove locking ring from
fuel tank sender assembly.
14.Remove fuel tank sender assembly from fuel
tank and discard seal.
NOTE: The fuel pump and fuel gauge tank unit
are integral parts of the fuel pump housing and
cannot be renewed separately
M88 0359
INSTRUMENTS
88-8 REPAIRS
Refit
1.Clean fuel tank sender assembly and mating
face.
2.Fit new fuel tank sender assembly seal to fuel
tank.
3.Fit fuel tank sender assembly to fuel tank.
4.Using LRT-19-009 fit and secure fuel tank
sender assembly locking ring to fuel tank.
5. Models with FBH: Connect FBH hose to fuel
tank sender assembly and secure with clip.
6.Fit and secure pressure relief, fuel feed and
return hoses to fuel tank sender assembly.
7.Remove container from beneath fuel tank.
8.Connect multiplug to fuel tank sender
assembly.
9.Fit fuel tank sender assembly access panel and
secure with screws.
10.Position carpet to floor and secure with
fasteners.
11.Reposition rear seat.
12.Close rear and tail doors.
13.Connect battery earth lead.
