FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD]

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Warning

• Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.

― Fuel may cause irritation if it comes in contact with skin and eyes.

― If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

• A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.

Fuel gauge sender unit (main)

Caution

• Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

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

2. Using the following procedure:

Fuel gauge indicates 3/4 or more

1. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 2.2].)

Fuel gauge indicates less than 3/4

1. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

3. Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

4. Remove the screws.

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5. While pressing the tabs of clip in the direction of arrows (1) shown in the figure, pull clip in the direction of arrow (2) to detach the tabs of clip from the service hole cover.

6. Remove the service hole cover.

7. Disconnect the connector.

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8. Disconnect the hose from the set plate while pressing the tabs of the clips in the direction of the arrows shown in the figure.

9. Remove the screws.

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10. Lift the set plate up and disconnect the connector.

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11. While pressing the tabs of the clip in the direction of arrows (1) shown in the figure, press the clip in the direction of arrow (2) to detach it from the set plate.

12. Move the retainer upward using a small flathead screwdriver or a similar tool.

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13. Pull out the fuel hose straight from the fuel pipe and disconnect it. (SeeQuick Release Connector Assembly Note.)

14. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from getting scratched or dirty.

15. Remove the set plate.

16. Remove the O-ring.

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17. Remove the nuts.

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

19. Install in the reverse order of removal.

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

Quick Release Connector Assembly Note

Note

• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

• If there is any malfunction, replace it with a new one.

2. Install the quick release connector.

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• Insert the fuel pipe straight to the end of the quick release connector.

• Push down the retainer using a finger.

― If the retainer cannot be pushed down, push the fuel pipe further to the quick release connector.

3. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

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

Fuel gauge sender unit (sub)

Caution

• If the servicing is performed with the fuel gauge indicating 1/2 or more, fuel leakage may occur because the fuel level surface is higher than the fuel gauge sender unit installation surface. When the fuel gauge indicates 1/2 or more, always drain the fuel before servicing so that the fuel tank level is 1/3 or less.

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

2. Using the following procedure:

Fuel gauge indicates 1/2 or more

1. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 2.2].)

Fuel gauge indicates less than 1/3

1. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

3. Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

4. Remove the screws.

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