Vibe 2003-2005

Fuel Level Sending Unit

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump mounting-FWD shown, AWD similar

     
    Rear seat cushion and floor service hole cover
     
    Fuel pump and vapor pressure sensor connectors
     
    Start and run the engine, until it stalls
     

  4.  
  5. Turn the ignition key to the LOCK position.

    Negative battery cable
     

  6.  
  7. Connect the fuel pump connector.

    Fuel tank protector, AWD vehicles
     
    Fuel tank main tube sub-assembly
     
    Fuel emission tube sub-assembly No. 1, FWD vehicles
     
    Fuel tank vent tube set plate. The plate is secured with 8 bolts on FWD vehicles, or 5 bolts on AWD vehicles.

    Click image to see an enlarged view

    Fig. The fuel tank vent tube set plate is secured with 8 bolts on FWD vehicles

     
    Fuel pump assembly, being careful not to damage the filter or bend the arm of the fuel sender gauge
     
    Fuel suction tube set gasket
     
    Fuel suction support No. 2
     
    Fuel pump rubber cushion
     
    Fuel sender gauge assembly. Unplug the connector, then use a screwdriver to unlock the gauge and slide it to remove.
     
    Fuel section plate sub-assembly
     
    Vapor pressure sensor
     
    Fuel pump harness
     
    Fuel pump
     
    Fuel pump filter
     
    Fuel pressure regulator and O-ring

    Click image to see an enlarged view

    Fig. Fuel pump assembly components-FWD vehicles shown, AWD similar

     

  8.  

To install:

  1. Install or connect the following:

    New regulator O-ring and regulator
     
    Fuel pump filter
     
    Fuel pump
     
    Vapor pressure sensor
     
    Fuel suction tube set gasket
     
    Fuel pump assembly
     
    Fuel tank vent tube set plate. Tighten the bolts to 53 inch lbs. (6 Nm).
     
    Connect the fuel emission tube sub-assembly
     
    Fuel tank main tube sub-assembly
     
    Fuel tank protector No. 2, AWD vehicles
     
    Negative battery cable. Check for fuel leaks.
     
    Floor service hole cover. Use butyl tape to seal the cover.
     
    Rear seat cushion
     

  2.  

Testing



  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the fuel pump and sender electrical connector.
    NOTE
    Do these tests within 10 seconds to prevent the coil from burning out. Keep the pump as far away from the battery as possible and always do the switching at the batter side.

  4.  
  5. Connect battery voltage to terminal 5 of the connector and a ground connection to terminal 4 of the connector. The fuel pump should operate. If not replace the pump.

    Click image to see an enlarged view

    Fig. Connect battery voltage to terminal 5 of the connector and a ground connection to terminal 4 of the connector. The fuel pump should operate. If not replace the pump

  6.  

 
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