Ameer Randolph
Replacing a fuel sending unit is a complex process that requires a number of steps. First, you must disconnect the fuel lines and electrical connections from the fuel sending unit. You will then need to clean the area around the plug and ensure it is free of any contaminants that could fall into the tank. Next, you should compare the old unit with the replacement unit to make sure it is compatible. If it is, you can fit the new fuel sending unit with the new gasket/O-ring, making sure the gasket is properly aligned between the fuel sending unit and the tank. Finally, you will need to reconnect all electrical connectors and snap the fuel lines back into place.
| Characteristics | Values |
|---|---|
| First step | Disconnect the fuel lines and electrical connections from the fuel sending unit |
| Tools required | Non-ferrous tool or punch, plastic pry tools, 14mm socket, tiny flat screwdriver, 10mm socket, torx screwdriver, plastic pry tools |
| Next steps | Clean the area around the plug, remove the retaining ring, pull the old fuel sending unit with the gasket/O-ring out of the tank |
| Compatibility | Compare the old unit with the replacement unit to make sure it is compatible |
| Installation | Fit the new fuel sending unit with the new gasket/O-ring, making sure the gasket is properly aligned between the fuel sending unit and the tank |
| Fuel pump sending unit | Transfer over the fuel line retainers |
| Fuel pump | Guide in the sending unit arm first |
| Retaining ring | Reinstall (if applicable) |
| Screws | Use the included washers to prevent leaks, and tighten in a star pattern |
| Electrical connectors | Reconnect |
| Fuel lines | Snap back in place |
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What You'll Learn
Disconnect the fuel lines and electrical connections from the fuel sending unit
Disconnecting the fuel lines and electrical connections from the fuel sending unit is a crucial step in replacing the unit. Here is a detailed guide on how to do this:
Firstly, ensure you have the correct tools for the job. You will need a non-ferrous tool or punch to remove the retaining ring. It is important to use a non-ferrous tool to avoid creating sparks that could ignite fuel vapours. You should also have some clean gas cans ready to drain the gas tank.
Next, release the fuel tank pressure according to the instructions in the vehicle's service manual. This is an important safety step to prevent fuel spraying out when you disconnect the lines. Then, drain the gas tank into the clean gas cans. Once the tank is empty, pull the tank out and remove the sending unit.
Now you are ready to disconnect the fuel lines and electrical connections. Clean the area around the plug first, making sure it is free of any contaminants that could fall into the tank. Then, carefully disconnect the fuel lines and electrical connections from the fuel sending unit. Take your time with this step to avoid any damage to the connections or fuel lines.
Once the fuel lines and electrical connections are disconnected, you can proceed to remove the old fuel sending unit. Pull the old unit, along with the gasket/O-ring, out of the tank. Be careful not to lose or damage the gasket/O-ring, as you will need to fit a new one when installing the replacement unit.
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Remove rear seats and rocker trim
To remove the rear seats, you will need plastic pry tools and a 14mm socket. There are four plastic hinge covers and eight bolts to remove. Start by prying off the hinge covers with the plastic pry tools, then remove the bolts with the socket.
The rocker trim can be removed using plastic pry tools. There are two trim pieces at each rear doorwell. Again, use the plastic pry tools to gently pry the trim pieces off, starting at one end and working your way around.
It is important to be careful when removing trim pieces to avoid damaging them. Work slowly and gently, prying from different angles if necessary, until the trim piece pops off.
Once the rear seats and rocker trim have been removed, you will have access to the fuel sending unit. Be sure to set the seats and trim pieces aside in a safe place so that you can reinstall them later.
Now you can move on to the next steps of replacing the fuel sending unit, which may involve removing the plastic steps at each rear door and the plastic seat anchor covers, as described in the forum post.
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Release the fuel tank pressure
To release the fuel tank pressure, follow the instructions in the vehicle's service manual.
The service manual will provide detailed, vehicle-specific instructions on how to safely release the fuel tank pressure. It is important to follow these instructions precisely to avoid any potential hazards.
The service manual will outline the steps to take, the tools required, and any safety precautions that need to be taken. It will also provide information on how to properly dispose of any released fuel or vapours.
By following the instructions in the service manual, you can ensure that the fuel tank pressure is released correctly and safely.
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Compare the old unit with the replacement unit
When replacing a fuel sending unit, it is important to compare the old unit with the replacement unit to ensure compatibility. The new unit should come with a new gasket/O-ring, which needs to be properly aligned between the fuel sending unit and the tank. If you are replacing a fuel pump sending unit, you will also need to transfer over the fuel line retainers.
The old and new units should be compared in terms of their physical dimensions, ensuring that the new unit will fit properly in the vehicle. The electrical connectors should also be checked to make sure they are compatible and can be reconnected correctly.
If the old unit uses screws, the new unit should also have screws and included washers to prevent leaks. These should be tightened in a star pattern. It is also important to check that the new unit has the correct Ohms, matching the manufacturer’s specifications, to ensure it is not faulty.
Finally, if the old unit has a retaining ring, this will need to be removed and transferred to the new unit. This should be done using a non-ferrous tool or punch to avoid any damage to the tank.
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Reinstall the retaining ring
To reinstall the retaining ring, you will need to use a non-ferrous tool or punch. Make sure the gasket is properly aligned between the fuel sending unit and the tank. If the fuel sending unit uses screws, be sure to use the included washers to prevent leaks, and tighten in a star pattern. Reconnect all electrical connectors and snap fuel lines back in place.
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Frequently asked questions
First, disconnect the fuel lines and electrical connections from the fuel sending unit. Then, clean the area around the plug and make sure it is free of any contaminants that could fall in the tank. Pull the old fuel sending unit with the gasket/O-ring out of the tank. Compare the old unit with the replacement unit to make sure it is compatible. Fit the new fuel sending unit with the new gasket/O-ring, making sure the gasket is properly aligned between the fuel sending unit and the tank. Reinstall the retaining ring (if applicable).
You will need a non-ferrous tool or punch to remove the retaining ring (if applicable). You may also need a tiny flat screwdriver, a 10mm socket, a torx screwdriver, and plastic pry tools.
If the Ohms do not move or match the manufacturer’s specifications, then the fuel sending unit is likely faulty and will need to be replaced. The biggest issue with fuel sending unit failures is bad fuel. The use of aggressive fuels, or additives in the tank, can corrode the contacts on the fuel sending unit, causing dead spots or a loss of signal.
