Replace Fuel Sending Unit
Replace Fuel Sending UnitWARNING:
^ Before performing any of the Service Procedures below, be certain there are no ignition sources (i.e., open flames, sparks, etc.) in or around the vehicle/work area.
^ Make sure the appropriate rated fire extinguisher is available for immediate use.
^ Use suitable protective gloves, safety glasses, or face shield.
CAUTION:
Use suitable covers to protect carpet, upholstery, etc.
NOTE:
The Fuel Sending Unit that you remove from the vehicle may look different from the new replacement service part (see Figure 43).
1. If the fuel tank is more than 3/4 full, use a suitable device to remove fuel from the fuel tank until the fuel level is 3/4 full or less.
2. Release the fuel pressure from the fuel system using CONSULT-II (or other suitable method). Follow the procedure in the "EC" section of the Service Manual.
3. Remove the Fuel Sending Unit as follows:
a. First, use shop air to clean the area around the Fuel Sending Unit and Mounting Flange (see Figure 35).
b. Then, apply Rust Penetrant (999MP-A3020P) to the Fuel Sending Unit Mounting Flange Bolts (see Figure 36). Allow the penetrant to "soak" for a few minutes.
c. Using hand tools ONLY, gently remove the Fuel Sending Unit Mounting Flange Bolts.
4. Remove the Fuel Sending Unit.
NOTE:
To disconnect the fuel return hose from the Fuel Sending Unit, do the following:
^ Push UP on the fuel return hose connector 1 to 2 mm (around 1/16-inch). See Figure 37A.
^ With the hose connector pushed UP, hold the two plastic tabs. See Figure 37B.
^ While holding the plastic tabs, pry DOWN on the hose connector with hose removal pliers (such as #47900, Lisle Corporation or equivalent). See Figure 37C.
NOTE:
The hose removal pliers (noted above) are available from TECH-MATE.
^ Cut and discard the old Fuel Sending Unit O-ring. You'll be installing a new O-ring later.
5. Inspect the Fuel Tank Sending Unit Mounting Flange and O-Ring Groove (see Figure 38 and 39).
6. Insert the Protective Cover (provided in Kit A or Kit B) in the Fuel Tank opening (see Figure 40).
CAUTION:
^ Make sure the Protective Cover is properly inserted/seated to prevent rust and debris from entering the Fuel Tank.
^ Make sure the appropriate rated fire extinguisher is available for immediate use.
7. Completely clean the Fuel Tank Sending Unit Mounting Flange and O-Ring Groove by hand using Scotch Brite Pad 3M #051131-07447 or a copper/bronze bristle brush. See Figure 41.
WARNING:
^ Do NOT use any power tools (pneumatic or electric) for cleaning the Fuel Tank Sending Unit Mounting Flange and O-Ring Groove.
^ Use proper care and precaution when working around gasoline.
^ Be certain there are no ignition sources (i.e., open flames, sparks, etc.) in or around the vehicle/work area.
^ Use suitable protective gloves, safety glasses, or face shield.
8. Use shop air to completely blow off/clean the Fuel Tank Sending Unit Mounting Flange and O-Ring Groove.
9. Install the new Fuel Sending Unit O-ring in the groove on the fuel tank.
10. Use the new mounting screws to install the Fuel Sending Unit on the fuel tank. Refer to the "FE" section of the applicable Service Manual.
^ Tighten the Fuel Sending Unit mounting screws to 2.0 - 2.5 N-m (0.20 - 0.26 kg-m, 17.4 - 22.6 in-lb).
IMPORTANT:
Make sure the Fuel Sending Unit Wire Harness Connectors are securely locked into position.
11. Apply Tectyl 517 (Bitumen) Wax Sealer to the Fuel Sending Unit Mounting Flange area as follows:
a. Completely clean and dry off (with shop air) the Mounting Flange area.
b. Apply ONLY Tectyl 517 (Bitumen) Wax Sealer (999MP-9G001P) around the outer edge of the Fuel Sending Unit Mounting Flange (see Figure 42).
^ Thoroughly shake the can of Wax Sealer to ensure complete mixing.
12. Re-assemble all parts you removed before (except the Fuel Sending Unit Inspection Cover and Body Cover) in the reverse order you removed them.
NOTE:
Make sure all Fuel/EVAP hoses are in good condition (no cracks, splits, etc.) and are securely reconnected to prevent leaks. Also, make sure the gas cap is installed and securely tightened.
13. Use CONSULT-II to check the Fuel Tank for leaks as follows:
a. Connect CONSULT-II.
b. Turn the ignition key to the ON position (with engine off).
c. Select: Engine, Work Support, EVAP System Close, and Start.
d. Attach the Vacuum Pump J-42909 to the vehicle's under hood EVAP System service port.
e. Use the Vacuum Pump to pressurize the EVAP System until the bar graph on the CONSULT-II screen reads half.
^ If there is NO pressure drop before 1 minute elapses (goes by), go to the next step.
^ If there is any pressure drop before 1 minute elapses (goes by), recheck all hoses/connections and perform the test again.
NOTE:
If you still have a leak, replace the Fuel Tank and go to the next step.
14. Install/tighten the Fuel Sending Unit Inspection Cover Bolts snug, being careful not to strip out the plastic inserts.
15. Install/tighten the Body Cover Plate Bolts to 3.7 - 5.0 N-m (0.38 - 0.51 kg-m, 33.0 - 44.3 in-lb).
16. Clear any engine diagnosis codes.
17. Start the vehicle and confirm proper engine running and fuel gauge operation.