Instruments - Fuel Gauge Always Reads Full
Classification:EL05-005
Reference:
ITB06-002
Date:
February 2, 2006
FUEL GAUGE ALWAYS READS FULL
APPLIED VEHICLE:
2004-05 QX56 (JA60)
APPLIED DATE:
Vehicles built before: December 9, 2004
IF YOU CONFIRM:
The Fuel Gauge stays on FULL:
^ Even though the fuel level in the tank is less than full.
AND/OR
^ After the vehicle is driven for an extended distance.
ACTION:
Use a suitable method to remove 5 to 10 gallons of gasoline from the fuel tank. Then, cycle the ignition key ON/OFF three times (leave it ON at the last cycle).
^ If the Fuel Gauge stays on FULL, replace the Fuel Level Sending Unit. See the Service Procedure for details.
^ If the Fuel Gauge does NOT stay on FULL, this bulletin does not apply. Look for other causes of the incident.
IMPORTANT:
The purpose of "ACTION" (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire Service Procedure as it contains information that is essential to successfully completing this repair.
PARTS INFORMATION
CLAIMS INFORMATION
Submit a Primary Failed Part (PP) line claim using the claims coding table.
TOOL INFORMATION
SERVICE PROCEDURE
CAUTION:
^ Follow all cautions and warnings in the Electronic Service Manual (ESM) when performing this procedure.
^ Wear suitable personal protective equipment (gloves, face shield, etc.) during this procedure.
^ Make sure the ignition switch is OFF before going to step 1, below.
^ Do NOT bend the Float Arm when handling the new Fuel Level Sending Unit.
1. Remove the Fuel Tank from the vehicle.
^ Refer to section FL of the applicable ESM for the removal instructions.
2. Remove the Fuel Pump Assembly from the Fuel Tank.
^ Refer to section FL of the applicable ESM for the removal instructions.
3. Remove the Fuel Level Sending Unit from the Fuel Pump Assembly as follows:
a. First press IN on the two Locking Tabs on either side of the Fuel Level Sending Unit (see Figure 1a). Then pull the Unit UP and OUT of the attachment slots (see Figure 1b).
b. Remove the brown Fuel Temperature Sensor from the white Plastic Retaining Clip (see Figure 2).
C. Remove the two Fuel Temperature Sensor Wires from the Securing Tab (see Figure 2).
d. Unplug the white 3-Wire Connector at the top of the fuel pump (see Figure 3).
^ Do NOT disturb the black 2-Wire Connector located next to the white connector.
e. Carefully cut the Tie-Wrap securing the harnesses to the black Corrugated Tubing (see Figure 3).
CAUTION:
Do NOT damage the wires or the wire insulation when cutting the Tie.Wrap.
4. Install the new Fuel Level Sending Unit as follows:
CAUTION:
Do NOT bend the Float Arm when handling the Fuel Level Sending Unit / Fuel Pump Assembly.
a. Slide the new Fuel Level Sending Unit into the attachment slots until the two Locking Tabs snap in place (see Figure 4).
^ Confirm the Locking Tabs are snapped in place by trying to move the Sending Unit up and down (it should not move).
b. Insert the brown Fuel Temperature Sensor into the white Plastic Retaining Clip (see Figure 4).
^ Make sure the "circular flange" of the Sensor is positioned between the Clip and the Rib.
c. Insert the two Fuel Temperature Sensor Wires into the Securing Tab (see Figure 4).
d. Connect the white 3-Wire Connector into the top of the Fuel Pump (see Figure 5).
e. Push and pull all connectors to make sure they are fully locked in place.
f. Use the new Tie-Wrap to secure all the wires to the black corrugated tubing. These include the three Fuel Level Sending Unit Wires and the two Fuel Pump Wires (see Figure 5).
^ Place the Tie-Wrap 100 mm (about 4 inches) from the top of the tubing.
^ Make sure the wires do not interfere with the movement of the float arm.
5. Carefully reinstall the Fuel Pump Assembly into the Fuel Tank per the ESM.
CAUTION:
Do NOT bend the Float Arm when re-installing the Fuel Pump.
6. Reinstall the Fuel Tank per the ESM.
7. Confirm the Fuel Gauge operates properly.
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