EMPI Aluminum Gas Tank Cap (Model 00-3538-0) Instruction Manual

1. Product Overview

The EMPI Aluminum Gas Tank Cap, Model 00-3538-0, is a replacement fuel cap designed for use with aluminum spun tanks. It is commonly applied in various off-road and classic vehicle types, including dune buggies, trikes, Volkswagen Bugs, Ghias, and Bajas. This cap is vented and features a chrome-plated aluminum construction for durability and appearance. It is engineered to fit spun aluminum fuel tanks that utilize a 2-notch filler neck.

Figure 1: Top view of the EMPI Aluminum Gas Tank Cap, showing its chrome finish and the safety warning label.

Key Features:

• Compatibility: Designed for spun aluminum fuel tanks with a 2-notch filler neck.
• Material: Constructed from chrome-plated aluminum.
• Functionality: Vented design.
• Installation Style: Twist-on.

2. Safety Information

Always prioritize safety when handling fuel system components. Fuel is highly flammable and its vapors can be explosive. Ensure adequate ventilation and avoid open flames or sparks when working near the fuel tank.

Warning: Fuel spray may cause injury. Always remove the gas cap slowly to allow any pressure to equalize, especially in warm conditions or after the vehicle has been running. Failure to do so may result in fuel spray and potential injury or fire hazard.

Keep out of reach of children. Do not ingest or inhale fuel vapors.

3. Package Contents

The EMPI Aluminum Gas Tank Cap package typically includes:

• One (1) EMPI Aluminum Gas Tank Cap (Model 00-3538-0)

4. Installation Instructions

Before installation, ensure the vehicle's engine is off and cool. Park the vehicle on a level surface and engage the parking brake. It is recommended to wear appropriate safety gear, including gloves and eye protection.

1. Preparation: Carefully remove the existing gas tank cap by twisting it counter-clockwise. If the old cap is difficult to remove, apply gentle, steady pressure.
2. Inspect Filler Neck: Examine the fuel tank's filler neck to ensure it is clean and free of debris or damage. Verify that the filler neck has a 2-notch design, which is required for proper fitment of this cap.
3. Position the New Cap: Align the EMPI Aluminum Gas Tank Cap with the filler neck. The cap features internal locking tabs designed to engage with the notches on the filler neck.

Figure 2: Underside view of the gas cap, illustrating the twist-on mechanism and seal.
4. Secure the Cap: Press the cap down gently and twist it clockwise until it clicks or tightens securely. Do not overtighten. The cap should feel snug and not easily turn further.
5. Verify Fitment: After installation, gently pull on the cap to ensure it is securely seated and cannot be easily removed without twisting.

5. Operation

To open the EMPI Aluminum Gas Tank Cap, twist it counter-clockwise slowly until it loosens and can be lifted off the filler neck. To close, align the cap with the filler neck, press down, and twist clockwise until it is securely tightened. Always ensure the cap is fully closed to prevent fuel leakage and evaporation.

6. Maintenance

Regular maintenance helps ensure the longevity and proper function of your gas tank cap.

• Cleaning: Periodically clean the exterior of the cap with a soft cloth and mild automotive cleaner. Avoid abrasive materials that could scratch the chrome finish.
• Seal Inspection: Inspect the rubber seal on the underside of the cap for cracks, hardening, or signs of wear. A damaged seal can lead to fuel leaks or improper venting. Replace the cap if the seal is compromised.
• Filler Neck Condition: Ensure the fuel tank's filler neck remains clean and free of rust or damage, which could affect the cap's seal and fitment.

7. Troubleshooting

If you encounter issues with your EMPI Aluminum Gas Tank Cap, consider the following:

• Cap Not Sealing Properly:
  • Check if the cap is fully tightened.
  • Inspect the rubber seal for damage or debris.
  • Verify the fuel tank's filler neck is clean and undamaged.
• Difficulty Removing/Installing Cap:
  • Ensure the cap is aligned correctly with the filler neck's notches.
  • Apply gentle, steady pressure when twisting. Do not force the cap.
• Fuel Odor:
  • A strong fuel odor may indicate a leak. Re-check the cap's seal and tightness.
  • Inspect the fuel tank and lines for any other leaks.

If problems persist, consult a qualified automotive technician.

8. Specifications

9. Warranty and Support

Specific warranty details for the EMPI Aluminum Gas Tank Cap (Model 00-3538-0) are typically provided at the point of purchase or by the retailer. Please refer to your purchase documentation for warranty coverage information.

For technical support or further assistance, please contact EMPI customer service or your authorized EMPI dealer. Contact information can usually be found on the manufacturer's official website or product packaging.