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Old 02-10-2007, 03:41 PM   #1
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Default Fix broken gas gauge (STEP BY STEP GUIDE)

A big thanxs to Hans for researching, performing and documenting this fix.

The original question asked was how to remove the ring...after enough pounding I got it. Thats what the first few replies are about....

To start you need to get the part mentioned on this page:
Aurora Club of North America (ACNA) Forum - gas gauge jumps..

Next you need to remove the part mentioned..just tap out the metal piece as mentioned.

Now we get to remove the fuel sending unit.

Start off by grabbing an energy drink and the items shown in the first picture.

Next we need to pull the Fuel pump relay. Its pointed out in this picture

Turn the engine over, it will run for a few seconds then die...

Next you want to remove the gas gap and fire the may sputter for a second then die....the fuel pressure is now relieved...if you dont believe me check the schrader valve on the fuel rail and will be bone dry. [b]This means there is no need to drain the fuel into a rag like the FSM says, it is already drained.

Locate access panel in trunk. Remove the 5 7MM bolts. Remove panel..make sure you shop vac the hell out of the surrounding area or use compressed air..then wipe it down and make it sparkling clean.

Unplug the quick connects and power plugs for the fuel pump/sender. A little gas will come out of each line so have a shop towel ready.

Using the recommended tool or a screwdriver and hammer, tap the retaining plate holding the fuel sender to the pump...after several HARD taps it will come out. Once you get it out you will notice a lot of dust and dirt underneath it that you could not clean earlier..using DUCT TAPE..carefully life up the debris. DO NOT allow any debrix into the tank.

Carefully remove fuel sender from vehicle, you need to tilt it backwards to clear the float piece on the sender, make sure you have a lot of shop towels laid in the trunk to adsorb the 10oz or so of fuel thats going to fall out.

Next turn the sender upside down and dump the remaining gas into a container like the one in the first picture.

Here is what the sender looks like:

Remove the sender from the housing by pulling the white plastic clip out.

Tap the retainer out of the wiper that contains the 2 fingers the read the fuel level...note how the one on the left, the fingers are completely worn down. this is bad.


Here is what the gauge says now

Do not drink and do this project. Commonly drinking leads to ciggerate smoking and thats a big no no when working around gasoline.
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