Fuel Temp. Sensor Installation Procedure

NOTE:
Record the fuel tank level according to the vehicles fuel gauge.

1. Install the new tank fuel temp. sensor as follows:

A. Use CONSULT to release fuel pressure from the vehicle's fuel system as follows:

1. Connect CONSULT.

2. Start the engine and let it idle.

3. Turn CONSULT on and touch start, engine, work support, fuel pressure release, and start.

4. Run the engine until it stalls. Then crank the engine 2 or 3 times to release remaining fuel pressure.

5. Turn the ignition switch off.

B. Empty the fuel (in the fuel tank) into a suitable container.

NOTE:
The fuel tank capacity is approximately 16 gallons (60 liters).

C. Lift up the vehicle.





D. Disconnect the fuel pump/gauge harness connector (see Figure 13).

E. Disconnect the fuel filler hoses, fuel supply hose, fuel return hose and the fuel vent hose from the fuel tank.





F. Remove the fuel tank protector plate (see Figure 14).





G. Support the fuel tank with a transmission jack (or suitable support device) and remove the 6 mounting bolts that secure the fuel tank (see Figure 15).





H. Remove the 2 bolts that secure the rear fuel tank support bracket. Remove the support bracket (see Figure 16).

I. Carefully remove the fuel tank from the vehicle.

J. Remove the 6 bolts that secure the fuel pump/gauge assembly.





K. Carefully lift up on the fuel pump/gauge assembly and disconnect the tank fuel temp. sensor harness connector. Remove the fuel pump/gauge assembly (see Figure 17).





L. Disconnect the tank fuel temp. sensor from the support bracket in the fuel tank. Remove the tank fuel temp. sensor from the fuel tank (see Figure 18).





M. Attach the sensor end of the new tank fuel temp. sensor to the support bracket in the fuel tank (see Figure 19). Route the connector end of the sensor up through the fuel tank opening.

NOTE:
When attaching the sensor end of the tank fuel temp. sensor to the support bracket, make sure the soldered connection or wires of the tank fuel temp. sensor do not contact the support bracket (see Figure 19).

N. Install the new fuel pump/gauge assembly cover 0-ring (see Figure 19).

0. Connect the tank fuel temp. sensor harness to the fuel pump/gauge assembly.

P. Reinstall the fuel pump/gauge assembly in the fuel tank. Tighten the 6 mounting screws to 2.0 - 2.5 N.m (0.20-0.26 kg-m, 17.4 - 22.6 in-lb).

Q. Reinstall the rear fuel tank support bracket. Tighten the 2 mounting bolts to 27 - 35 N.m (2.8 - 3.6 kg-m, 20 - 26 ft-lb).

R. Reinstall the fuel tank. Tighten the 6 mounting bolts to 27 - 35 N.m (2.8 - 3.6 kg-m, 20 - 26 ft-lb).

S. Reinstall the fuel tank protector plate. Tighten the mounting bolts to 27 - 35 N.m (2.8 - 3.6 kg-m, 20 - 26 ft-lb).

T. Reconnect the fuel filler hoses, fuel supply hose, fuel return hose and the fuel vent hose to the fuel tank.

U. Reconnect the fuel pump/gauge harness connector to the vehicle harness.

V. Return the appropriate amount of fuel to the fuel tank (refer to the fuel tank gauge level reading).