Fuel Gauge Sender: Service and Repair

FUEL GAUGE UNIT AND PUMP ASSEMBLY REPLACEMENT




1. Remove the rear seat cushion.
2. Remove the protector.
3. Bleed the residual pressure from inside the fuel pipe line to prevent the fuel from spraying out.
4. Disconnect the hose and connector connections, and then remove the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly.
5. Check to be sure that the fuel tank packing is not damaged or deformed, and then securely install the packing in the fuel tank.

CAUTION: If the packing is installed to the fuel tank while it is still attached to the fuel pump module, the lip of the packing may become bent or break off, and fuel leaks may then result.

NOTE: If the packing is damaged or deformed replace with new packing.

6. Apply soapy water to the inside of the packing, and then install the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly.

CAUTION: Do not tilt the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly when installing.




7. After applying soapy water to the outside thread of the fuel tank. Use the special tool to tighten the cap to the specified torque so that the marks on the fuel tank and the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) are aligned.

CAUTION: Make sure that the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) does not turn together with the cap when tightening the cap. If the mating marks are not aligned, the position of the float will not be correct and the fuel gauge indicator light and the fuel level gauge will not operate properly.





CAUTION: The packing should be installed as shown in the illustration.

8. Check for leaks from the installation of the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly by the following procedure.
1. Apply soapy water to the circumference of the cap.
2. Choke the vapor hose and main hose, apply an internal pressure of 10 kPa (1.5 psi) or less from the return hose and check to be sure that no bubbles form in the soapy water.