Instruments - Intermittent/Inoperative Fuel Gauge
XT310-05DATE
02/05
Amended 03/05
X-TYPE
MODEL
2002 MY-ON
X-TYPE
VIN
C0001-ON
Fuel Gauge Failure or Intermittent Operation - Fuel Level Sender Available Separately - Replacement Procedure
Remove and destroy Bulletin XT310-05 dated 02/05.
Replace with this Bulletin.
Revisions are marked with a bar
Issue:
This Technical Bulletin is for information only, to inform dealers that if there is a fault with the fuel level sender unit, the fuel level sender unit can now be replaced as a separate part.
Action:
To install a new fuel level sender unit, follow the procedure below.
FUEL PUMP SENDER REPLACEMENT - FIRST-TIME REPAIR ONLY
Note:
There are two stages to the process for replacement of the fuel sender, one for a first-time repair, when the harness needs to be replaced, and another for any subsequent repairs when just the sender can be replaced.
1. Remove the fuel tank (see Global Technical Reference GTR Workshop Manual, section: 310-01, SRO 19.55.01).
2. Remove the fuel pump module(s) (see Global Technical Reference GTR Workshop Manual, section: 310-01, SRO 19.45.08).
3. Drain any remaining fuel into a suitable container
4. Cut the wires to the level sender the (Illustration 1).
5. Using suitable pliers, release the locking tang of the sender the from the housing (Illustration 2).
6. Remove the sender the from the module.
7. Release the connector from the pump; note the orientation of the connector body as it passes through the flange.
Note:
Fuel pump shown; jet pump similar.
8. Depress the retaining tangs of the connector body and release the connector from the flange (Illustration 3).
9. Withdraw the harness through the flange.
Installation
Note:
Fuel pump shown; jet pump similar.
Note:
Make sure the connector body locates firmly into the flange and that the 0-ring seals to the flange.
10. Position the new flange harness through the flange in the same orientation as the original harness (Illustration 4).
11. Connect the new harness to the pump.
12. Locate the new sender tile into the housing, making sure that the sender fully seats at each edge and that the tang clips are fully home.
Note:
Fuel pump shown; jet pump similar.
13. Connect the new sender tile to the harness connector (Illustration 5).
14. Install the fuel pump module(s) (see Global Technical Reference GTR Workshop Manual, section: 310-01, SRO 19.45.08).
15. Install the fuel tank (see Global Technical Reference GTR Workshop Manual, section: 310-01, SRO 19.55.01).
For subsequent repairs to install a new fuel level sender
16. Install a new fuel level sender unit (see Global Technical Reference GTR Workshop Manual, section: 310-01).
Parts Information:
Warranty Information:
Warranty claims should be submitted quoting the information found in the table.
This will result in payment of the stated time and, where applicable parts/miscellaneous expense codes as listed.
Disclaimer