Service Procedure

SERVICE PROCEDURE

1. Remove the Fuel Pump Assembly from the vehicle.

^ Refer to section FL of the applicable Service Manual for removal information.

^ Make sure to follow all Service Manual warnings and cautions.

2. Remove the Fuel Gauge Sender Unit from the Fuel Pump Assembly as follows:

a. First, press in on the two locking tabs on the sides of the Fuel Gauge Sender Unit

b. Then, pull the unit UP and OUT of the attachment slots





^ For Type A see Figure 1





^ For Type B see Figure 2





c. Remove the Fuel Temperature Sensor from the Plastic Retaining Clip.

d. Remove the wires from the Securing Tab.





e. Unplug the White Wire Connector at the top ofthe fuel pump.

^ DO NOT disturb the Black Wire Connector located next to the white Wire connector.

f. Carefully cut the tie-wrap securing the harnesses to the corrugated tubing.

CAUTION:
DO NOT damage the wires or the wire insulation when cutting the Tie-Wrap.





3. Install the new Fuel Gauge Sender Unit as follows (see Figure 5):

CAUTION:
Do not bend the float arm when handling the new Fuel Gauge Sender Unit / Fuel Pump Assembly.

a. Slide the new Fuel Gauge Sender Unit into the attachment slots until the two Locking Tabs snap in place.

^ Confirm the Locking Tabs are snapped in place by trying to move the Sender Unit up and down (it should not move).

b. Insert the Fuel Temperature Sensor into the Plastic Retaining Clip.

^ 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.





d. Connect the White Wire Connector into the top of the Fuel Pump (see Figure 6).

e. Pull and push 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 (see Figure 6).

^ New tie-wrap is included with the new sender unit.

^ Make sure all wires are tied together (3 fuel level sending unit wires and 2 fuel pump wires).

^ Place the Tie-Wrap 90 mm (about 3.5 inches) from the top of the tubing.

^ Make sure the wires do not interfere with the movement of the float arm.

4. Carefully reinstall the Fuel Pump Assembly back into the vehicle in reverse of removal.

^ IMPORTANT: Use a new seal (O-Ring) when reinstalling the Fuel Pump Assembly.

^ Refer to the Service Manual as needed.

CAUTION:
DO NOT bend the Float Arm when reinstalling the Fuel Pump.

5. Confirm the Fuel Gauge operates properly.