Fuel Gauge Sender: Service and Repair
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION
Fuel Gauge Sender Unit (Main)
1. Remove the rear seat cushion. Rear Seat Removal/Installation
2. Drain the fuel from the fuel tank. Removal and Replacement
3. Disconnect the negative battery cable.
4. Remove the fuel pump unit. Removal and Replacement
5. Remove in the order indicated in the table.
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)
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".
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. Park the vehicle on a level surface.
2. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution
3. Disconnect the quick release connector from the fuel pump unit. Quick Release Connector Removal/Installation
4. Connect the hose to the fuel pump unit and drain the fuel into a container used for collecting gasoline.
5. Drain the fuel from the fuel tank using the following procedure.
Using M-MDS
- Connect the M-MDS to the DLC-2
- Using the simulation function "FP", start the fuel pump. On-Board Diagnostic Test
CAUTION:
- Shorting the wrong terminal of the check connector may cause malfunctions. Make sure to short only the specified terminal.
Without using M-MDS
- Ground check connector terminal F/P to the body using a jumper wire.
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.
- Turn the ignition switch to the ON position and operate the fuel pump.
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. Stop the fuel pump using the following procedure.
Using M-MDS
- Using the simulation function "FP", stop the fuel pump. On-Board Diagnostic Test
Without using M-MDS
- Turn the ignition switch to the LOCK position and stop the fuel pump.
- Disconnect the jumper wire.
7. Disconnect the negative battery cable. Removal and Replacement
8. Remove the service hole cover.
9. Remove in the order indicated in the table.
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.
10. Remove the fuel gauge sender unit (sub) from the fuel gauge sender unit stay.
11. Install in the reverse order of removal.
12. Complete the "AFTER SERVICE PRECAUTION".
Cap Removal Note
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.
1. Remove the cap using the SST.
Cap Installation Note
1. Align the convex of the set plate with the notch of the retainer as shown in the figure.
NOTE:
- Remove the residue of gasoline on gasket or cap completely. Any residue of gasoline can make the set plate turn round and prevent it from fixing.
2. Adjust the start mark of the fuel tank with the center one out of three rib lines of the cap, then turn it around 360° degrees by hand as shown in the figure.
- 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.
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.
3. 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 2.
Rotation angle (Total angle for Step 2 and Step 3)
- 580-620°
Cap tightening torque (approx.)
- 80-180 Nm {8.2-18 kgf-m, 60-132 ft-lbf}