Secondary Fuel Gauge Sending Unit Removal And Installation

Secondary Fuel Gauge Sending Unit Removal and Installation

Special Tools Required

- Fuel Sender Wrench 07AAA-S0XA100

Removal (4WD)

1. Relieve the fuel pressure Service and Repair.

2. Remove the rear seat cushion Rear Seat Removal / Installation.

3. Remove the access panel (A) from the right side of the floor.





4. Disconnect the secondary fuel gauge sending unit 4P connector (B).

5. Using the special tool, loosen the locknut (A).






6. Remove the locknut (A), and lift up the secondary fuel gauge sending unit (B) from the fuel tank.





7. Disconnect the transfer tube (C), and remove the secondary fuel gauge sending unit.

Installation (4WD)

1. Temporarily attach a new base gasket (A) to the secondary fuel gauge sending unit (B), position the mark on the transfer tube (C) up, connect the transfer tube (D), then insert the secondary fuel gauge sending unit partially into the fuel tank.

NOTE:

- Be careful not to damage the new base gasket.
- Make sure the clamp (E) is positioned as shown.
- Be careful not to bend the secondary fuel gauge sending unit.
- Do not coat the base gasket with oil.





2. Transfer the base gasket (A) from the secondary fuel gauge sending unit to the fuel tank.





3. Align the marks (B) on the fuel tank and the secondary fuel gauge sending unit, then insert the secondary fuel gauge sending unit into the fuel tank until the fuel tank unit rests on top of the base gasket.

NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.

4. Tighten a new locknut (A) by hand with a new locknut plate (B).

NOTE: Before tightening, align the mark (C) on the locknut with the start of the threads (D).






5. Using the tool, tighten a new locknut to the specified torque.

NOTE:

- After tightening, make sure the marks (A) are still aligned.
- After installation, check the base gasket, visually or by hand, to be sure it is not pinched.





6. Connect the secondary fuel gauge sending unit 4P connector.

7. Reconnect the negative cable to the battery, and turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat two or three times, then make sure there are no fuel leaks.

8. Install the parts in the reverse order of removal.