Fuel Sending Unit - Installation
Section2
Group
23
No
0046
Year
00
Month
01
850/S70/V70/C70 Coupe'
1994-
Reference: This Service Bulletin replaces the previous Service Bulletin 23-0046 from October 1999, which should be discarded.
Fuel sending unit, replacement
Background
This service bulletin describes how to install the new style fuel sending unit. Only the new style sending unit is available as a spare part.
The new type of sending unit can be installed on S70/V70/C70 vehicles and on the 800 series vehicles from chassis No. listed here.
Model Factory Chassis No.
850-4 drs Turbo 1, 3 131664-
850-5 dr Turbo 2 037635-
850-4 drs w/o Turbo 1,3 043709-
850-5 drs w/o Turbo 2 048625-
Material Quantity Part No.
Gauge 1 9463238
Sending unit 1 See parts information system
Gasket 1 See parts information system
Replacement of fuel sending unit
Fuel sending unit, replacement Special tools: 999 5486
1
Preparations Station wagon
Raise the front hatch.
Remove the four screws for the hatch.
Pull hatch backward.
Pull away carpeting and fold down rear seat back rest
Sedan
Fold forward right side backrest.
Remove:
- Trunk carpet, and pull away right side wheel housing panel (On some vehicles the panel is made of hard material and must be removed from the trunk).
- Wire and connector attachments. The attachment is secured with two clips over the access cover for the sending unit.
- Remove the two access covers for the sending unit and fuel pump.
- Protective cap covering sending unit retaining nut (if applicable). In some cases it may be necessary to loosen fuel tank retaining straps, along with clamp for filler neck, and reposition tank to remove protective cap.
Caution!
The fuel tank MUST be supported before the screws for the tank straps are loosened.
2
Mark up
Before removing old sending unit, place gauge as per illustration.
Place a piece of masking tape on the floor board, under the aim tab.
Make two lines on the tape, using the two slits on the tab as template.
3
Harness
Separate the connector for the sending unit.
Move the harness from the sender over to the right side of the vehicle.
Attach a string or similar to the connector as per illustration.
Carefully pull over the harness with the connector to the access hole of the sending unit.
Note!
Place the string so that the harness of the new sending unit can be pulled back over again.
4
Remove fuel sending unit
Caution!
Place the retaining nut back on the threaded neck if the new sending unit is not installed immediately. The threaded neck may deform if left open.
Remove the retaining nut with special tool 999 5486.
Carefully pull up the sending unit half way, letting the fuel inside the tube drain out.
Caution!
Ensure so that no fuel spill occurs while lifting the sending unit out of the vehicle.
Remove the sending unit with the gasket.
5
Install new fuel sending unit
Note!
The mark (arrow) on the sending unit must be pointing within the marks on the tape.
Install new gasket on sending unit.
Lubricate the top surface of the sending unit to avoid twisting white tightening the retaining nut. Use petroleum jelly or equivalent.
Carefully insert the new sending unit into the tank.
6
Alignment of the sending unit
Align the sending unit as per illustration.
Install the retaining nut and torque to 30 Nm (22 ft. lbs). Check installation of sending unit with gauge as per illustration.
7
Route harness
Attach the string to the connector of the sending unit. Carefully pull the harness over to the access hole for the fuel pump.
Ensure that the harness is moved back to the left side of vehicle.
Install sending unit connector and mount connectors to the bracket.
8
Installing removed parts
Install:
- Protective cap over sending unit If applicable.
- Torque screws for fuel tank straps 25Nm (20 ft.lbs) if applicable.
- Cover plates for access holes.
- Harness bracket and connectors.
- Panels and carpeting over spare wheel.
Ensure proper operation of fuel gauge.
WARRANTY STATEMENT: Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.
Operation No. Labor description Time allowance
38618-2 Fuel sending unit replacement according to SB 23-0046 0.5 hr