Left

REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Release Procedure.
3. Raise the vehicle.
4. Remove the rear wheel and tire assembly.
5. Clean all of the fuel connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
6. Drain the fuel tanks. Refer to Draining Fuel Tanks (Pump Inoperative) or Draining Fuel Tanks (Pump Operational).
7. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
8. Disconnect the quick-connect fittings from the fuel sender. Refer to Fuel Line Coupling (Plastic Collar).
9. Cap all of the fuel pipes.
10. Disconnect the fuel sender electrical connector.
11. Remove the fuel tank strap/shield.
12. Support the fuel tank.
13. Remove the fuel sender attaching bolts.
14. Remove the float arm retaining clip and the float arm.
15. Carefully remove the fuel sender with the gasket.
16. Discard the fuel sender gasket.
17. Discard the fuel sender attaching bolts.
18. Clean the gasket sealing surfaces.


INSTALLATION 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 and the fuel sender attaching bolts when reinstalling the fuel sender assembly.


IMPORTANT: Always install a new fuel pump strainer before reinstalling the fuel sender assembly. A fuel pump strainer that has been exposed to fuel will not unfold in the fuel tank and may block full travel of the float arm.


1. Install a new fuel pump strainer in the same position as noted during disassembly. Push on the outer edge of the strainer ferrule until the strainer is fully seated.
2. Install a new fuel sender gasket on the fuel sender using the new fuel sender mounting bolts to hold the gasket in place.




3. Fold the strainer three times so that the amount of space occupied by the strainer is about equivalent to the diameter of the fuel sender reservoir.
3.1. Fold the long side of the strainer over (1 over 2).
3.2. Fold 3 over 4 and hold the strainer in the folded position.
4. Insert the fuel sender through the fuel tank opening.
5. Release the strainer once the strainer is in the fuel tank. The strainer will spring back to its full position.
6. Continue inserting the fuel sender through the fuel tank opening. It may be necessary to rotate the fuel sender in order to facilitate the installation.
6.1. Look through the fuel tank opening to ensure that the long side of the strainer is visible. The strainer should be approximately one inch from the tank opening.
6.2. If the strainer is not visible, rotate the fuel sender clockwise and counterclockwise about 90 degrees. Rotating the fuel sender will free up the strainer. The strainer should become visible at the tank opening.

IMPORTANT: Do not bend or twist the float arm.

7. Install the float arm and the float arm retaining clip.

Description:

8. Install the fuel sender assembly attaching bolts.


CAUTION: Do not over tighten the fuel sender assembly attaching bolts. Use a torque wrench in order to obtain the proper torque. The diameter of the threaded portion of the bolt is much smaller than the bolt head. Over tightening the bolt may cause the bolt to break. Tighten the fuel sender assembly attaching bolts in sequence to 3 Nm (27 lb. in.).





9. Connect the fuel sender fuel feed pipe (1) (jet pump to left tank), the fuel return rear pipe (2), and the fuel feed rear pipe (3). Refer to Quick Connect Fittings (Plastic Collar).
10. Connect the fuel sender electrical connector.




11. Install the fuel tank strap/shield.
12. Install the fuel tank strap/shield bolts.
12.1. Install the net hole bolt (3).
12.2. Install the slot location bolt (1).
12.3. Install the remaining bolts (2 and 5). Tighten the fuel tank strap/shield bolts to 25.5 Nm (19 lb. ft.).
13. Install the rear wheel and tire assembly.
14. Lower the vehicle.
15. Refill the fuel system.
16. Install the fuel filler cap.
17. Connect the negative battery cable.
18. Inspect for leaks.
18.1. Turn the ignition switch ON for 2 seconds.
18.2. Turn the ignition switch OFF for 10 seconds.
18.3. Turn the ignition switch ON.
18.4. Check for fuel leaks.