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Daewoo Nubira. Manual - part 159

Description

Page

Fuel Level Sensor Procedures

2 of 7

August, 2001

4. Disconnect the Wiring Harness Electrical

Connector from the Fuel Pump Module.

5. Turn the ignition switch to the "ON" position.

6. Using a suitable DVOM, measure voltage at

the Wiring Harness Electrical Connector
between terminal 1 and chassis ground. If a
5-V reference voltage is not present, repair
the open circuit between terminal B5 of the
ECM/PCM and the Wiring Harness Electrical
Connector. If a 5-V reference voltage is
present, go to the next step.

7. Measure the voltage at the Wiring Harness

Electrical Connector between terminals 1 and
6. If a 5-V reference voltage is not present,
repair the open circuit between terminal 6 of
the Wiring Harness Electrical Connector and
terminal D8 of the ECM/PCM. If a 5-V
reference voltage is present, go to the next
step.

8. Turn the Ignition Switch to the "OFF" position.

9. Reconnect the Wiring Harness Electrical

Connector to the Fuel Pump Module.

10. Remove the Fuel Pump Relay from the

Engine Compartment Fuse/Relay Box.

11. Start the engine and allow it to idle until the engine stalls. Crank the engine an additional

10 seconds, then turn the Ignition Switch to the "OFF" position.

Note: The engine should stall in less than 10 seconds once Fuel Pump Relay is

removed.

12. Remove the Fuel Filler Cap.

13. Disconnect the Fuel Outlet Hose from the Fuel Pump Module.

14. Disconnect the Fuel Tank Return Hose from the Fuel Pump Module.

15. Disconnect the Wiring Harness Electrical Connector.

16. Using a suitable hammer and brass drift, release the Fuel Pump Module Retaining Ring

by rotating it counterclockwise.

17. After removing the Fuel Pump Module Retaining Ring, remove the Fuel Pump Module

from the Fuel Tank.

CAUTION: Removing components from a sealed fuel system exposes fuel vapors to

outside oxygen and possible sources of combustion. A fuel system should
only be opened in a properly ventilated area. Special caution should be
used when removing components from a fuel tank or fuel system. Removal
of such components should only be done away from open flame (torches,
lit cigarettes, heater pilots or other flames however minor) or sparks
(mechanical, electrical or otherwise) that could cause fuel vapors to ignite.

Terminal “1”

Wiring Harness Electrical Connector

Terminal “6”

Terminal “1”

Description

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Fuel Level Sensor Procedures

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August, 2001

21. Slowly move the Fuel Level Sensor Float Arm

from the “empty” position to the “full” position
while observing the Fuel Level Sensor voltage
indications on the Scan Tool EVAP Data
Screen.

22. Confirm that the voltage makes a smooth

transition from 0.7 to 2.7 volts.

23. If the voltage "dips" or "spikes," at any point

throughout the voltage range, replace the Fuel
Level Sensor.

18. Reconnect the Wiring Harness Electrical

Connector to the Fuel Pump Module.

19. Turn the Ignition Switch to the "ON" position.
20. Connect the Scan 100 Scan Tool to the

vehicle Data-Link Connector (DLC) and go to
the EVAP Data Screen to view the Fuel Level
Sensor voltage
Screen Navigation Order:
Select “Diagnostic” 8 Choose “model year” 8
Choose “vehicle type” 8 Select “Powertrain”
8 Choose “transmission type” 8 Select “Data
Display” 8 Select “Engine Data” 8 Select
“EVAP Data”).

FUEL LEVEL SENSOR REPLACEMENT
PROCEDURE:

Removal

1. The Fuel Pump Module has a single (in-tank)

sub-harness that must be disconnected from
the Fuel Pump Module Mounting Flange
Connector.

2. Using a small pair of needle-nosed pliers,

remove and retain the secondary terminal lock
from the sub-harness electrical connector.

3. Using a suitable terminal release tool (similar to

Snap-on #YA500GM), depress the lock tang for
terminals 1 and 6, then pull the terminals out
through the back of the connector.

Note: The Fuel Level Sensor Terminals have

a beveled edge which requires proper
orientation when reinstalling in the
connector. Carefully note their
location by wire color in the connector
prior to removal.

Volts

Empty

Full

0.7

2.7

Note: Voltage sweep
should be steady with
no “dips” or “spikes”.

Fuel Level Sensor

Fuel Pump Module

Mounting Flange
Connector

Terminal Release Tool

Sub-Harness
Electrical Connector

Secondary Terminal Lock

Description

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Fuel Level Sensor Procedures

4 of 7

August, 2001

5. Disengage the Fuel Level Sensor wires from

the retaining hook at the top of the Fuel Pump
Module Body, then pull the cut wire ends out
of the fuel pump body through the built-in
tube.

4. Using a suitable pair of diagonal cutters, cut

off the two (2) Fuel Level Sensor Terminals
previously released/removed from the sub-
harness connector, then discard those
terminals.

6. Pull the Low Fuel Level Sensor from its

bracket.

7. Using a small flat-blade screwdriver, release

the Low Fuel Level Sensor Bracket from the
Fuel Pump Module Body by prying it in the
direction shown. The bracket will slide
through the retaining rail as you pull it free of
the Fuel Pump Module Body.

Note:

Prying in the opposite direction may
cause damage to the lock that retains
the Low Fuel Sensor Bracket.

8. Remove the Fuel Level Sensor by prying it in

the same direction from the same retaining rail
that previously held the Low Fuel Sensor
Bracket.

Prying Direction

Retaining Hook

Remove Terminals

Fuel Level Sensor

Low Fuel Level
Sensor Bracket

Description

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Fuel Level Sensor Procedures

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August, 2001

11. Guide the Fuel Level Sensor Body onto the

retaining rail on the Fuel Pump Module Body.
Slide it fully into place on the retaining rail. An
audible "click" will be heard as it locks into it’s
proper position.

Note: Failure to properly lock the Fuel Level

Sensor into place will affect its accuracy.

12. Route the Fuel Level Sensor wires through the

built-in tube in the Fuel Pump Module Body.

Installation

9. Temporarily wrap the new Fuel Level Sensor

wire terminals with electrical tape.

10. Route the wire through the groove at the bottom

of the Fuel Level Sensor as you route it around
to the back of the Fuel Level Sensor Body.

Note: Failure to properly route the wire in the

groove may cause the wire to be
damaged as the Fuel Level Sensor is
installed.

13.Route the Fuel Level Sensor wires through the

retaining hook on top of the Fuel Pump
Module Body.

14.Remove the electrical tape, then insert the

Fuel Level Sensor Terminals into the Fuel
Pump Module Sub-harness Electrical
Connector. Ensure that the terminals are
properly reinstalled (as noted previously) and
that the correct wire colors are in their proper
connector location. Also, verify that the
terminals are locked into position by gently
tugging on the wires after installation.

Note: The forward-most edge of the beveled

terminal face should be oriented
towards the "outboard" edges of the
terminal housing.

15. Once the terminals are properly positioned,

reinstall the secondary terminal lock into the
connector. Reconnect the sub-harness
connector to the Fuel Pump Module Mounting
Flange Connector.

Groove

Fuel Level Sensor Wires

Sub-Harness
Electrical Connector

Install Terminals

Mounting Flange
Connector

Secondary Terminal Lock

Content .. 157 158 159 160 ..