SRX 2004-2005

Fuel Level Sending Unit

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Removal & Installation



Primary

CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.


NOTE
This procedure requires the use of fuel tank sender wrench, special tool J45747 or equivalent.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the fuel tank hoses.
  4.  
  5. Disconnect the electrical connector from the primary fuel tank module.
    NOTE
    Do not allow the tool to come in contact with the fuel pipes while unlocking the cam lock ring.

  6.  
  7. Rotate the cam lock ring counter-clockwise using the J45747.

    Click image to see an enlarged view

    Fig. Fuel tank sender wrench

  8.  
  9. Remove the cam lock ring from the fuel tank.
    NOTE
    The primary fuel tank module (1) is horizontal in the installed position, but pivots vertically for removal.

  10.  
  11. Carefully lift the primary fuel tank module (1) from the fuel tank only enough to access the transfer tube (2).

    Click image to see an enlarged view

    Fig. Primary fuel tank module (1) and transfer tube (2)

  12.  
  13. Pull the locking mechanism away from the module.
  14.  
  15. Remove the transfer tube from the module.
  16.  
  17. Remove the primary fuel tank module from the fuel tank.
  18.  
  19. Remove the primary fuel tank module seal from the module. Do not reuse the seal.
  20.  

To install:


NOTE
Ensure the seal bead is facing the fuel tank.

  1. Place the new primary fuel tank module seal (1) over the module (2).

    Click image to see an enlarged view

    Fig. Positioning the new primary fuel tank seal (1)

  2.  
  3. Grasp the transfer tube (2) from inside the fuel tank.
  4.  
  5. Position the module (1) near the module opening.
  6.  
  7. Connect the transfer tube (2) to the module (1).
    NOTE
    Ensure the fuel level float is free from binding while inserting the module.



    Click image to see an enlarged view

    Fig. Primary fuel tank module (1) and transfer tube (2)

  8.  
  9. Carefully insert the primary fuel tank module (1) into the fuel tank.
  10.  
  11. Press the primary fuel tank module (1) downward, aligning the module to the encapsulated ring.
  12.  
  13. Position the cam lock ring to the fuel tank.
    NOTE
    Do not allow the tool to come in contact with the fuel pipes while locking the cam lock ring.

  14.  
  15. Rotate the cam lock ring clockwise using the J45747 until fully seated.
  16.  
  17. Connect the electrical connector to the primary fuel tank module.
  18.  
  19. Install the fuel tank hoses.
  20.  

Secondary

NOTE
This procedure requires the use of fuel tank sender wrench, special tool J45747 or equivalent.


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the fuel tank.
  4.  
  5. Disconnect the electrical connector from the secondary fuel tank module.
  6.  
  7. Rotate the cam lock ring counter-clockwise using the J45747.

    Click image to see an enlarged view

    Fig. Remove the cam lock ring using fuel tank sender wrench

  8.  
  9. Remove the cam lock ring from the fuel tank.
  10.  
  11. Carefully lift the secondary fuel tank module (2) from the fuel tank only enough to access the transfer tube (1).

    Click image to see an enlarged view

    Fig. Secondary fuel tank module (2) and transfer tube (1)

  12.  
  13. Pull the locking mechanism away from the module.
  14.  
  15. Remove the transfer tube from the module.
  16.  
  17. Remove the secondary fuel tank module from the fuel tank.
  18.  
  19. Remove the secondary fuel tank module seal from the module. Do not reuse the seal.
  20.  

To install:


NOTE
Ensure the seal bead is facing the fuel tank.

  1. Place the new secondary fuel tank module seal over the module.

    Click image to see an enlarged view

    Fig. Positioning the new fuel tank seal (1)

  2.  
  3. Grasp the transfer tube from inside the fuel tank.
  4.  
  5. Position the module near the module opening.
  6.  
  7. Connect the transfer tube to the module.
    NOTE
    Ensure the fuel level float is free from binding while inserting the module.

  8.  
  9. Carefully insert the secondary fuel tank module into the fuel tank.
  10.  
  11. Press the secondary fuel tank module downward, aligning the module to the encapsulated ring.
  12.  
  13. Position the cam lock ring to the fuel tank.
  14.  
  15. Rotate the cam lock ring clockwise using the J45747 until fully seated.
  16.  
  17. Connect the electrical connector to the secondary fuel tank module.
  18.  
  19. Install the fuel tank.
  20.  

Testing





Click image to see an enlarged view

Fig. Fuel level sensor connector terminal identification

  1. With the ignition OFF , disconnect the harness connector at the primary and secondary fuel level sensors.
  2.  
  3. While sweeping the primary fuel level sensor through its full range of motion, test for a minimum value less than 41 ohms and a maximum value greater than 119 ohms of resistance between signal terminal A and the low reference terminal D. If not within the specified range, replace the primary fuel level sensor.
  4.  
  5. While sweeping the secondary fuel level sensor through its full range of motion, test for a minimum value less than 41 ohms and a maximum value greater than 119 ohms of resistance between signal terminal A and the low reference terminal D. If not within the specified range, replace the secondary fuel level sensor.
  6.  

 
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