| Removal and Installation Removal All except vehicles with diesel engine | | -
Remove the fuel pump and sender unit.
For additional information, refer to: Fuel Pump Module (310-01 Fuel Tank and Lines, Removal and Installation).
| Vehicles with diesel engine | | -
Remove the fuel level sensor.
For additional information, refer to: Fuel Level Sensor (310-01 Fuel Tank and Lines, Removal and Installation).
| Vehicles built up to 05/2004 | | -
CAUTION:Do not cut the cable tie. To avoid damaging the fuel line, cut the wires. NOTE:Make a note of the wiring harness routing to aid installation. Cut all the wires between the fuel pump and sender unit and the top flange. | | | -
Pull the cut wires from under the cable tie. | | | -
Disconnect the fuel level resistor card electrical connector. - Discard the electrical connector.
| | | -
Disconnect the fuel pump and sender unit electrical connector (if equipped). - Discard the electrical connector.
| Vehicles built 05/2004 onwards | | -
CAUTION:Do not cut the ground (green) wire. CAUTION:Do not cut the cable tie. To avoid damaging the fuel line, cut the wire. NOTE:Make a note of the wiring harness routing to aid installation. Cut the yellow wire (with a soldered joint) between the fuel pump and sender unit and the top flange. | | | -
Pull the cut wire from under the cable tie. | | | -
NOTE:Diesel engine variants only have 2 wires. Disconnect the fuel level resistor card electrical connector. - Discard the electrical connector.
| | | -
Disconnect the electrical connector from the fuel level resistor card. | All vehicles | | -
Using needle nose pliers, remove the fuel level resistor card. - Press the locking tangs.
- Remove the fuel level resistor card.
- Discard the fuel level resistor card
| Installation Vehicles built 05/2004 onwards | | -
Connect the electrical connector to the fuel level resistor card. | | | -
NOTE:Diesel engine variants only have 2 wires. Connect the fuel level resistor card electrical connector. | Vehicles built up to 05/2004 | | -
Connect the fuel pump and sender unit electrical connector (if equipped) from the new fuel level resistor card. | | | -
NOTE:Make sure that the electrical connector is fully locked into place. Connect the fuel level resistor card electrical connector. | All vehicles | | -
CAUTION:Do not touch the fuel level resistor card surface with tools or hands. Failure to follow this instruction may result in damage to the fuel level resistor card. NOTE:Make sure that the locking tangs are in the fully locked position. NOTE:Make sure that the wiring harness is routed around the fuel line, in line with the original installation. Install the new fuel level resistor card into the fuel pump and sender unit or the fuel level sensor. | | | -
Make sure that the float rod and arm are able to sweep their full ranges without contacting or fouling on any wires. | | | -
CAUTION:Do not over-tighten the cable tie. Over-tightening may lead to a collapse of the fuel line. Secure all wires using a new cable tie adjacent to the existing cable tie. | Vehicles with diesel engine | | -
NOTE:Install a new fuel level sensor gasket. Install the fuel level sensor.
For additional information, refer to: Fuel Level Sensor (310-01 Fuel Tank and Lines, Removal and Installation).
| All except vehicles with diesel engine | | -
NOTE:Install a new fuel pump and sender unit gasket. Install the fuel pump and sender unit.
For additional information, refer to: Fuel Pump Module (310-01 Fuel Tank and Lines, Removal and Installation).
| |
