Fuel Gauge Sender: Service and Repair

FUEL GAUGE TANK UNIT - 6 CYL

Fig 1:

Fig 2:

RENEW

WARNING:
THIS OPERATION RESULTS IN FUEL AND FUEL VAPOR BEING PRESENT IN THE ATMOSPHERE.
FUEL VAPOR IS EXTREMELY FLAMMABLE, THEREFORE GREAT CARE MUST BE TAKEN WHEN WORK IS CARRIED OUT ON THE FUEL SYSTEM.
THE FOLLOWING PRECAUTIONS MUST BE STRICTLY ADHERED TO:
1 NO SMOKING IN THE WORK AREA.
2 "NO SMOKING" WARNING SIGNS MUST BE POSTED ROUND THE AREA.
3 A C02 FIRE EXTINGUISHER MUST BE CLOSE AT HAND.
4 DRY SAND MUST BE AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.
5 EMPTY THE FUEL FROM THE TANK USING SUITABLE FIREPROOF EQUIPMENT.
6 FUEL MUST NOT BE EMPTIED INTO A PIT.
7 THE WORKING AREA MUST BE WELL VENTILATED.
8 THE FUEL MUST BE EMPTIED INTO AN AUTHORIZED EXPLOSION PROOF CONTAINER.
9 MAINTENANCE PERSONNEL SHOULD HAVE UNDERTAKEN SPECIALIST TRAINING BEFORE BEING ALLOWED TO REPAIR COMPONENTS ASSOCIATED WITH THE FUEL SYSTEM.

Disconnect the battery earth lead.
Empty the fuel tank into an explosion proof container using suitable fireproof equipment.
Remove the luggage compartment floor carpet.
Remove the luggage compartment front liner.
Note and disconnect the cables from the fuel gauge tank unit (Fig. 1).
Rotate the fuel gauge tank unit securing ring using Service Tool 18G 1001 (Fig. 2).
Remove the securing ring (Fig. 2).
Remove the fuel gauge from the tank.
Remove and discard the gasket (Fig. 2).

Note: Ensure a new sealing gasket and locking ring is fitted when a replacement fuel gauge tank unit is fitted.

Fit a new gasket to the new fuel gauge tank unit.
Fit and fully seat the fuel gauge tank unit into the tank.
Using Service Tool 18G 1001, fit and secure the locking ring (Fig. 2).
Reconnect the fuel gauge tank unit cables.

Note: The top terminal (1 Fig. 1) is the positive supply terminal; the centre terminal (2 Fig. 1) is the earth terminal. The bottom terminal (3 Fig. 1) is the warning lamp terminal and should be blanked off with an insulation cover to prevent incorrect connection.

Refit the luggage compartment front liner.
Refit the luggage compartment floor carpet.
Reconnect the battery earth lead.


SERVICE TOOLS
Locking ring spanner 18G 1001