Fuel System - Fuel Level Sender Availability/Replacement
XJ310-03DATE
10/05
XJ range
Fuel Level Sender -
Available Separately From Pump -
Replacement Procedure
MODEL
2004-05 MY
XJ range
VIN
G00442-G49700
Issue:
This Technical Bulletin is for information only, to inform dealers that if there is a fault with the fuel level sender unit, the fuel level sender unit can now be replaced as a separate part.
Action:
To install a new fuel level sender unit, follow the procedure below.
FUEL PUMP SENDER REPLACEMENT - FIRST-TIME REPAIR ONLY
First-time repair only
Note:
There are two stages to the process for replacement of the fuel sender, one for a first-time repair, when the harness needs to be replaced, and another for any subsequent repairs to install a new fuel level sender from VIN G00421 to G49700.
Note:
Check DDW to see if a previous first time repair has been carried out on the fuel level sender unit, before carrying out the Service Instruction.
1. Remove the fuel pump module(s) (see Global Technical Reference GTR Workshop Manual, section: 310-01).
2. Drain any remaining fuel into a suitable container
Note:
Fuel pump shown; jet pump similar.
3. Cut the wires to the level sender tile (Illustration 1).
Note:
Fuel pump shown; jet pump similar.
4. Using suitable pliers, release the locking tang of the sender tile from the housing (Illustration 2).
5. Remove the sender tile from the module.
6. Release the connector from the pump; note the orientation of the connector body as it passes through the flange.
Note:
Fuel pump shown; jet pump similar.
7. Depress the retaining tangs of the connector body and release the connector from the flange (Illustration 3).
8. Withdraw the harness through the flange.
Installation
Note:
Fuel pump shown; jet pump similar.
Note:
Make sure the connector body locates firmly into the flange and that the O-ring seals to the flange.
9. Position the new flange harness through the flange in the same orientation as the original harness (Illustration 4)
10. Connect the new harness to the pump.
11. Locate the new sender tile into the housing, making sure that the sender fully seats at each edge and that the tang clips are fully home.
Note:
Fuel pump shown; jet pump similar.
12. Connect the new sender tile to the harness connector (Illustration 5).
13. Install the fuel pump module(s) (see Global Technical Reference GTR Workshop Manual, section: 310-01).
For subsequent repairs to install a new fuel level sender
1. Install a new fuel level sender unit (see Global Technical Reference GTR Workshop Manual, section: 310-01).
Parts Information:
Warranty Information:
Warranty claims should be submitted quoting the information found in the table.
This will result in payment of the stated time and, where applicable parts/miscellaneous expense codes as listed.
Note:
Repair procedures are under constant review, and therefore repair times are subject to change. The times quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
Disclaimer