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FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION

BHE092260960W01

## Fuel Gauge Sender Unit (Main)

1. Remove the rear seat. (See REAR SEAT REMOVAL/INSTALLATION.)

2. Drain the fuel from the fuel tank. (See FUEL PUMP UNIT REMOVAL/INSTALLATION.)

3. Disconnect the negative battery cable.

4. Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION.)

5. Remove in the order indicated in the table.

1 | Fuel gauge sender unit stay (See Fuel gauge sender unit stay removal note.)
2 | Fuel gauge sender unit

6. Install in the reverse order of removal.

### Fuel gauge sender unit stay removal note

  Caution

  • A deformed fuel gauge sender unit arm could cause the fuel level to be indicated incorrectly. When holding the fuel gauge sender unit stay, grasp any part other than the arm portion.

1. Rotate the fuel gauge sender unit stay counter-clockwise to remove it.

## Fuel Gauge Sender Unit (Sub)

### Removal

> Warning

  • Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTIONS".
  • Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel gauge sender unit (sub) removal/installation, always complete the "Fuel leak inspection after fuel gauge sender unit (sub) installation".

1. Follow the precautions before performing any work operations, and prevent the fuel from spilling from the fuel system.

2. Drain fuel from the fuel tank.

> Warning

  • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching a vehicle.

  Caution

  • When the fuel gauge indicates 3/4 or more, the fuel level is higher than the installation surface of the fuel pump and the fuel suction pipe bracket. Due to this condition, fuel may spill or leak out when performing this procedure. Before performing this procedure, always drain out fuel so that the fuel tank is half full or less (according to the fuel gauge needle).

  (1) Disconnect the quick release connector (engine compartment side). (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.)
  (2) Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
  (3) Ground check connector terminal F/P to the body using a jumper wire.

> > Caution

  • Shorting the wrong terminal of the check connector may cause malfunctions. Make sure to short only the specified terminal.

  (4) Turn the ignition switch to the ON position and operate the fuel pump for approx. 20 min.

> > Caution

  • The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.

  (5) When essentially no fuel is being discharged from the hose, turn the ignition switch to the LOCK position.

  Note

  • When operating the fuel pump with a full fuel tank, fuel discharge will become erratic after approx. 10 min but will continue for approx. 10 min more and then essentially no fuel will be discharged. At this time the fuel gauge needle will be at the halfway position.

  (6) Disconnect the jumper wire.
  (7) Disconnect the negative battery cable.
  (8) Remove the driver's side rear seat. (See REAR SEAT REMOVAL/INSTALLATION.)
  (9) Remove the service hole cover.
  (10) Remove the cap using the SST.

> > Caution

  • The cap could be damaged if the SST is used with any play between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

  (11) Remove the packing.
  (12) Remove the fuel suction pipe bracket.
  (13) Drain any remaining fuel from the hole where the fuel suction pipe bracket was removed.

3. Rotate the fuel gauge sender unit stay clockwise to remove it.

  Caution

  • A deformed fuel gauge sender unit arm could cause the fuel level to be indicated incorrectly. When holding the fuel gauge sender unit stay, grasp any part other than the arm portion.

4. Remove the fuel gauge sender unit (sub) from the fuel gauge sender unit stay.

### Installation

1. Install the fuel gauge sender unit (sub) to the fuel gauge sender unit stay.

2. Insert the fuel suction pipe bracket into the installation hole.

3. Align the fuel suction pipe bracket alignment marks and the retainer notch as shown in the figure.

4. Install the packing.

5. Align the positions of the cap and retainer as shown in the figure, and tighten them one full rotation by hand.

  • If the retainer and cap cannot be tighten by hand, remove the cap, verify that there is no damage or misalignment on the retainer and cap, and then tighten again.

6. While keeping the alignment mark and the retainer notch aligned, tighten the cap to the rotation angle and specified torque using the SST.

  • If the specified torque cannot be obtained even when the cap is rotated to the specified rotation angle, replace with a new cap and retainer and repeat Step 3.

  Caution

  • The cap could be damaged if the SST is used with any play between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

  Rotation angle

  50-140°
  (Total angle for Step 5 and Step 6 is 410-500°.)

  Cap tightening torque

  80-135 N·m {8.2-13.7 kgf·m, 59-99 ft·lbf}

7. Install the service hole cover.

8. Install the rear seat. (See REAR SEAT REMOVAL/INSTALLATION.)

9. Connect the negative battery cable.

10. Inspect all parts by performing the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE.)

11. Perform the "Fuel leak inspection after fuel gauge sender unit (sub) installation". (See Fuel leak inspection after fuel gauge sender unit (sub) installation.)

### Fuel leak inspection after fuel gauge sender unit (sub) installation

1. Drive the vehicle from a standstill or brake suddenly 5-6 times at a low speed.

2. Stop the vehicle and verify that there is no fuel leakage from the fuel tank.