Hi all,

My original fuel sender unit was stuck solid and did not work so I purchased an after market sender unit and replaced accordingly.

Beware! There are issues if it is done wrong as I found out. Installation of the CAM ring if done incorrectly will cause leaks!

The fuel sender unit is located behind the spare wheel and under the carpet covering the fuel tank.

Correct steps:

1: Disconnect negative terminal from battery
2: Take a photo of the wiring and remove the wires
3: Using a white marker or similar MARK ONE OF THE SMALL TABS in relation to the fuel tank body (White marker line)
4: Drain fuel tank with clear hose into portable fuel cans until you are sure the fuel has been emptied
5: Using a hammer and large flat head screw driver, tap one of the 3 small tabs anticlockwise gently until the CAM ring pops loose.
6: Remove the CAM ring
7: Using a small screw driver or similar, release the old sender unit by working under the disc plate, careful not damage gasket underneath
8: Remove the old sender unit
9: Clean the existing gasket with a rag and check its condition. (Replace if necessary)
10: Gently insert the new sender by leaning it backwards so it clears the strengthening partition inside the fuel tank.
11: Ensure it is inserted the correct way up and locks into position and does not rotate.
12: Carefully insert the CAM ring and turn clockwise by hand until it lightly locks the cams into the 3 x stationary tab pockets.
13: Using the Flathead screwdriver, gently tap one of the tabs clockwise until the tab just touches the tab pocket and lines up with the MARKER lines in (3) above.

The CAM ring when tapped into place creates force onto the sender unit disc plate and seals onto the rubber gasket. Fill tank and carefully check for leaks!

NOTE: If you hammer the tabs too far you will bend the 3 x matching steel CAM pockets and the CAM ring will work it's way out of position and fuel will leak into the boot when you fill it back up!!!

Hope this can be of help!

Cheers
CF