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Home >> Mazda >> 2002 >> Tribute LX, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Instrumentation/Driver Info) >> Fuel Gauge Sender Unit Removal/Installation >> Fuel Gauge Sender Unit (Sub) >> Removal

Fuel Gauge Sender Unit (Sub): Removal

WARNING: This page is about a different car, the 2004 Mazda RX-8. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTIONS".
  • Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel gauge sender unit (sub) removal/installation, always complete the "Fuel leak inspection after fuel gauge sender unit (sub) installation".
  1. Follow the precautions before performing any work operations, and prevent the fuel from spilling from the fuel system.
  2. Drain fuel from the fuel tank.
    WARNING:
    • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching a vehicle.
    CAUTION:
    • When the fuel gauge indicates 3/4 or more, the fuel level is higher than the installation surface of the fuel pump and the fuel suction pipe bracket. Due to this conditions, fuel may spill or leak out when performing this procedure. Before performing this procedure, always drain out fuel so that the fuel tank is half full or less (according to the fuel gauge needle).
    1. Disconnect the quick release connector (engine compartment side). (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
    2. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
      Fig 1: Locating Quick Release Connector
      G01344786Courtesy of MAZDA MOTORS CORP.
    3. Ground check connector terminal F/P to the body using a jumper wire.
      CAUTION:
      • Shorting the wrong terminal of the check connector may cause malfunctions. Make sure to short only the specified terminal.
    4. Turn the ignition switch to the ON position and operate the fuel pump for approx. 20 min. 
      Fig 2: Connecting Check Connector Terminal F/P To Body Ground
      G01344787Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.
    5. When essentially no fuel is being discharged from the hose, turn the ignition switch to the LOCK position.
      NOTE:
      • When operating the fuel pump with a full fuel tank, fuel discharge will become erratic after approx. 10 min  but will continue for approx. 10 min  more and then essentially no fuel will be discharged. At this time the fuel gauge needle will be at the halfway position.
    6. Disconnect the jumper wire.
    7. Disconnect the negative battery cable.
    8. Remove the driver's side rear seat. (See REAR SEAT REMOVAL/INSTALLATION .)
    9. Remove the service hole cover.
      Fig 3: Removing Service Hole Cover
      G01344788Courtesy of MAZDA MOTORS CORP.
    10. Remove the cap using the SST. 
      CAUTION:
      • The cap could be damaged if the SST is used with any play between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.
    11. Remove the packing.
    12. Remove the fuel suction pipe bracket.
    13. Drain any remaining fuel from the hole where the fuel suction pipe bracket was removed.
      Fig 4: Removing Cap
      G01344789Courtesy of MAZDA MOTORS CORP.
  3. Rotate the fuel gauge sender unit stay clockwise to remove it.
    CAUTION:
    • A deformed fuel gauge sender unit arm could cause the fuel level to be indicated incorrectly. When holding the fuel gauge sender unit stay, grasp any part other than the arm portion.
  4. Remove the fuel gauge sender unit (sub) from the fuel gauge sender unit stay.
    Fig 5: Locating Fuel Gauge Sender Unit
    G01344790Courtesy of MAZDA MOTORS CORP.
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