Things you'll need:- shop towels
- 12mm socket
- 8mm socket
- 8mm socket
- needle nose pliers
- trim tool (make it tons easier)
- gas tank that isn't full (makes it cleaner)
- beer (if you're showing up at a buddies house to do it)
- fuel unit assy 85111AC012 (drivers side level sensor & pickup)
- level sensor (m) 42081FE021 (level sensor that goes on passenger side fuel pump assy)
Here's where the access panels are, towards the front of the trunk:
Undo the trim clips & pull back the trunk lining on the passenger side:
So you can un-clip the fuel relay & then start the car till it runs out've fuel pressure:
But there's no way you'll do the rest of this from inside the trunk.
Remove the back seats:
-2 12mm bolts at the bottom of the seat bottom & it lifts out
-4 12mm bolts along the bottom of the seat back and you can press it towards the back of the car to unclip it and lift it out.
Here you can almost see the access panel, you just have to remove those vertical bars & their carpeted trim:
-remove the 4 12mm bolts & the 4 "christmas tree" style trim clips
Now you can easily access the panel:
-undo the 3 philips screws
-unclip the plug & pull off the rubber line (keep the towel ready)
-undo the 6 8mm nuts to remove it.
Here's the old assy (with the sock on the bottom already moved to the new assy):
New (blue
) assy:
Here's the shiny new assy with it's hose hooked up, wires plugged in, and 6 8mm bolts done back up.
Now onto the passenger side & fuel pump assy:
-undo the 4 philips screws holding on the panel
-Unclip the fuel lines (have the rag ready!)
-the one pointed towards the front of the vehicle will almost always spray.
-pull off the rubber hoses
-undo wiring
-undo 8(?) 8mm nuts
Here's the fuel pump assy removed from the tank:
Here's the new level sender:
Hrm, looks like this one will involve some soldering (to the fuel temp sensor?)
Don't be an idiot! Remove the level sender (1 phillips screw), and the fuel temp sensor (friction fit) and go do your soldering *far* away from the gas fumes!The level sensor assembly really is just held on with one (very tight) phillips screw.
-solder the fuel temp sensor to the new level sensor.
Installation is the reverse of removal. Gas gauge when I arrived there:
Gas gauge afterwards: