Fuel System/Instruments - Fuel Gauge Reads Empty With Full Tank

Classification: EL12-073

Reference: ITB12-075

Date: November 21, 2012

2009-2012 FX; FUEL GAUGE READS "EMPTY" AFTER FILLING TANK

APPLIED VEHICLES: 2009 - 2012 FX35 and FX50 (S51)

IF YOU CONFIRM:
An applied vehicle has a fuel gauge that registers "empty" after the fuel tank has been filled up full.

ACTION:

1. Remove the main fuel level sensor unit, fuel filter, and fuel pump assembly (fuel pump module).

2. Remove the spring from the fuel pump module just removed.

3. Install the spring onto the new fuel pump module.

^ With the spring installed, the new fuel pump module will have two (2) springs.

4. Install the new fuel pump module into the vehicle.

^ For repairs, refer to SERVICE PROCEDURE.





PARTS INFORMATION





CLAIMS INFORMATION

IMPORTANT:
The purpose of ACTION (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire SERVICE PROCEDURE as it contains information that is essential to successfully completing the repair.

SERVICE PROCEDURE

NOTE
Perform all repairs in a clean work environment.

1. Remove the fuel pump module from the vehicle.

^ Refer to the B ENGINE> FL Fuel System section of the Electronic Service Manual (ESM), if needed.

2. Remove the spring as follows:





a. Remove the wires from the retention feature (see Figure 1).





b. Push down on the top of the fuel pump module, and then remove the clip from the spring loaded rod with a suitable tool (see Figure 2).

NOTE:
There is only one clip on both old and new fuel pump modules.





c. Raise the top of the fuel pump module until the rods pull out completely (see Figure 3).





d. Remove the spring (see Figure 4).

3. Disassemble the new fuel pump module the same way as the old one.

4. Install the spring from the old fuel pump module onto the new one.

^ When reassembled, the new fuel pump module will have two springs, one on each rod.





5. With the springs installed, insert the rods into the holes of the fuel pump module base.

6. Install the clip from the new fuel pump module at its original location, nearest to the float.

^ To access where the clip mounts to the rod, push down on the top of the fuel pump module.

^ Make sure the top of the fuel pump module does not bind when moved up and down.

7. Reposition the wires under the retention feature.

^ The "green" and "black" wires do NOT go under the retention feature.

8. Install the fuel pump module in the fuel tank.

^ Refer to the B ENGINE> FL Fuel System section of the ESM, if needed.

9. Verify the fuel gauge reads correctly.