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How to Install Moeller Permanent Fuel Tanks

For your safety and for best results, read the following instructions completely before installation.

Before you install:

  • Organize all the hand tools you will need to complete installation of your permanent fuel tank. Necessary tools may include a tape measure, a flat-blade screwdriver, and pliers or wrench.

  • For best results and ease of installation, we recommend using Moeller's Permanent Fuel Tank Installation Kit (35723) not included. This kit provides the additional hardware and hoses, including a a stainless steel deck fill and chrome-plated brass thru-hull vent, suggested for a proper below deck tank installation.

  • Determine the best placement of your fuel tank, positioning it where the vent and fuel hose connections to deck wil form the shortest line. Make sure that the electrical sending unit is still accessible in this location.

  • Replace an existing fuel tank by removing the old unit.

  • Proper Fuel Tank Installation

  • Secure fuel tank into position. We recommend using our stainless steel Permanent Fuel Tank hold down kit (35710), may not be included with your tank.

  • IMPORTANT: Do not use foam to secure tank in place. Resin fuel tanks require a multidimensional expansion area of 2.3% at all times; foaming a tank in place removes the chance for hydrocarbon expansion and will void tank warranty.

  • Attach Fuel Fill Hose:

  • Slide two large hose clamps onto fuel fill hose and leave loose.

  • Check hose length from deck fill point to tank and trim as needed.

  • Slip the hose over the tank fill fitting and secure by tightening clamps into place 1/4: from the end of the hose.

  • Tighten the second clamp into place, leaving an 1/8" gap between the two clamps to ensure that the claps do not touch (see Figure 2). Note: Coast Guard guidelines requires the use of two hose clamps at each end of the fuel fill hose.

  • Connect an earth-end-ground wire to one of the two terminals found at the base of your tank's fill neck and use the stainless steel split ring lock washer and screw fitting to secure.

  • Important: to avoid a dangerous build-up of static electricity in your fuel system, make sure to employ an earth to ground hook-up to your tank. Likely grounding sites may include metal surfaces on your engine mount or outdrive. Grounding wire should not be attached to a painted surface and should be checked regularly for corrosive buildup.

  • Attach Vent Hose:

    (see Figure 1, Step 2)
  • If your tank does not have a molded on vent, thread a hose barb into your tank's vent. Do not over-tighten. We recommend the additional use of a gasoline and diesel resistant seal compound to guard against leakage.

  • Slide a small hose clamp onto vent hose and leave loose.

  • Check hose length from thru-hull vent to tank and trim as needed to avoid kinking.

  • Slide end of vent hose over the vent fitting and secure in place by tightening hose clamp 1/4" from hose end.

  • Attach Fuel Withdraw Hose

    (See Figure 1, Step 3)
  • Thread a hose barb into your tank's fuel withdraw. Do not over-tighten. (See Figure 2) We recommend the additional use of a gasoline and diesel resistant seal compound to guard against leakage.

  • Slide a hose clamp onto withdraw hose and leave loose.

  • Check length of hose and trim as needed to avoid kinking.

  • Slip hose over tank withdraw fitting; secure in place by tightening hose clamp 1/4" from end of hose.

  • For a no leak install:

    (See Figure 3)
  • A leak test should be conducted around seals and connections. Pressurize the tank to 3 psi then use soapy water to look for air bubbles around these areas. If unfamiliar with this procedure, seek professional assistance.

  • Proper wiring Installation:

    (See Figure 4)
  • Connect sender wire from fuel gauge to the threaded screw terminal on the fuel sender. Use attached nut and washer to secure wire in place.

  • Connect a grounding wire to the 1/4" fasson terminal on fuel sender.

  • Important: If you are unsure of any of these detailed procedures, seek professional assistance.

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