FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD]

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Warning

•  Always keep sparks and flames away from fuel when servicing the fuel system. Fuel can be easily ignited which could cause serious injury or death, and damage to equipment.

•  Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Line Safety Procedure, while referring to the BEFORE SERVICE PRECAUTION.

•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching a vehicle.

Caution

•  If the fuel gauge level indicates 3/4 or more, the fuel surface is higher than the fuel pump unit and fuel gauge sender unit installation surface. If servicing is performed under this condition, fuel leakage could result. Always drain the fuel before performing the operation and keep the fuel in the fuel tank at less than half.

SKYACTIV-G 2.0, SKYACTIV-G 2.5

Fuel gauge sender unit (main)

Note

•  For the fuel gauge sender unit removal/installation, refer to the fuel pump removal/installation because the fuel gauge sender unit is integrated with the fuel pump. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

Fuel gauge sender unit (sub)

1.  Perform the "Fuel Line Safety Procedure" referring to the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

2.  If the fuel gauge level indicates 3/4 or more, refer to the "FUEL DRAINING PROCEDURE" and drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

3.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)(See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT i-stop)].)

4.  Remove the following parts:

(1)  Rear seat cushion (6:4 split type) (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

(2)  Rear seat under installation bolt (4:2:4 split type) (See REAR SEAT REMOVAL/INSTALLATION.)

(3)  Rear scuff plate (See REAR SCUFF PLATE REMOVAL/INSTALLATION.)

5.  Partially peel back the floor covering.

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6.  Remove the screws.

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7.  Remove the service hole cover.

8.  Disconnect the connector.

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9.  Remove the screws.

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10.  Remove the fuel gauge sender unit (sub).

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11.  Install in the reverse order of removal.

12.  Perform the fuel leakage inspection referring to “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

SKYACTIV-D 2.2

Fuel gauge sender unit (main)

1.  Perform the "Fuel Line Safety Procedure" referring to the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

2.  If the fuel gauge level indicates 3/4 or more, refer to the "FUEL DRAINING PROCEDURE" and drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 2.2].)

3.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

4.  Remove the following parts:

(1)  Rear seat cushion (6:4 split-type seat) (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

(2)  Rear seat under installation bolt (4:2:4 split-type seat) (See REAR SEAT REMOVAL/INSTALLATION.)

(3)  Rear scuff plate (See REAR SCUFF PLATE REMOVAL/INSTALLATION.)

5.  Partially peel back the floor covering.

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6.  Remove the screws.

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7.  Remove the service hole cover.

8.  While pressing the tabs of clip A in the direction of arrows (1) shown in the figure, pull clip A in the direction of arrow (2) to detach the tabs of clip A from the fuel gauge sender unit (main).

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9.  Detach clip A.

10.  Disconnect the connector.

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11.  Disconnect the hose from the fuel gauge sender unit (main) while pressing the tabs of clips B in the direction of the arrows shown in the figure.

12.  Remove the screws.

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13.  Insert a tape-wrapped flathead screwdriver into the gap between clip C and the hose shown in the figure.

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14.  Move the flathead screwdriver in the direction of the arrow shown in the figure to detach clip C from the hose.

15.  Disconnect the hose.

16.  Remove the fuel gauge sender unit (main).

17.  Remove the O-ring.

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18.  Install in the reverse order of removal.

19.  Perform the fuel leakage inspection referring to “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

Fuel gauge sender unit (sub)

1.  Perform the "Fuel Line Safety Procedure" referring to the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

2.  If the fuel gauge level indicates 3/4 or more, refer to the "FUEL DRAINING PROCEDURE" and drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 2.2].)

3.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].)

4.  Remove the following parts:

(1)  Rear seat cushion (6:4 split-type seat) (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

(2)  Rear seat under installation bolt (4:2:4 split-type seat) (See REAR SEAT REMOVAL/INSTALLATION.)

(3)  Rear scuff plate (See REAR SCUFF PLATE REMOVAL/INSTALLATION.)

5.  Partially peel back the floor covering.

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6.  Remove the screws.

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7.  Remove the service hole cover.

8.  Disconnect the connector.

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9.  Remove the screws.

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10.  Remove the fuel gauge sender unit (sub).

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11.  Install in the reverse order of removal.

12.  Perform the fuel leakage inspection referring to “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)