Fuel Sending Unit, Replacement (GROUP 23, NO. 0046)

FUEL SENDING UNIT, REPLACEMENT

TECHNICAL SERVICE BULLETIN

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.

REPLACEMENT OF FUEL SENDING UNIT

Fuel sending unit, replacement 

Special tools: 999 5486

1. Preparations (see Fig 1 )
   1. 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.

   2. 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.
   Fig 1: Accessing Sending Unit

   
2. Mark up

   Before removing old sending unit, place gauge as per illustration (see Fig 2 ).

   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.

   Fig 2: Placing Gauge

   
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 (see Fig 3 ).

   Fig 3: Attaching String To Connector

   

   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 (see Fig 4 )
   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.

   Fig 4: Removing Fuel Sending Unit

   
5. Install new fuel sending unit (see Fig 5 )
   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 while tightening the retaining nut. Use petroleum jelly or equivalent.

   Carefully insert the new sending unit into the tank.

   Fig 5: Installing New Fuel Sending Unit

   
6. Alignment of the sending unit

   Align the sending unit as per illustration (see Fig 6 ).

   Fig 6: Aligning Sending Unit

   

   Install the retaining nut and torque to 30 Nm (22 ft. lbs).

   Check installation of sending unit with gauge as per illustration (see Fig 7 ).

   Fig 7: Checking Installation of Sending Unit

   
7. Route harness (see Fig 8 )

   Attach the string to the connector of the sending unit.

   Carefully pull the harness over to the access hole for the fuel pump.

   Fig 8: Routing Harness

   

   Ensure that the harness is moved back to the left side of vehicle.

   Install sending unit connector and mount connectors to the bracket (see Fig 9 ).

   Fig 9: Installing Connectors to Bracket

   
8. Installing removed parts

   Install:

   • Protective cap over sending unit if applicable.
   • Torque screws for fuel tank straps 25 Nm (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.