1998 Rodeo (UE)/Amigo (UA) Fuel Gauge Inaccuracy (Supercedes SB97-02-L009)

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1 1998 Service Bulletins TSB SB98-02-L Rodeo (UE)/Amigo (UA) Fuel Gauge Inaccuracy (Supercedes SB97-02-L009) ISSUE DATE: NOVEMBER 1998 Affected Vehicles 1998 Rodeo (UE) and Amigo (UA) models. Service Information Condition: Some affected vehicles may experience a condition in which the instrument panel fuel gauge reads inaccurately. In some cases, the fuel gauge needle will not move up to the "F" (FULL) mark after the fuel tank is completely filled. Possible Cause: Abnormal output values from the fuel gauge sending unit due to increased contact resistance. Correction: Replace the fuel gauge sending unit assembly using the Fuel Gauge Sender Service Kit and reprogram the PCM using the special calibration for the new sending unit. Do not replace the entire Fuel Pump and Sender (FPAS) assembly to correct the above condition. Service Procedure Important: For 3.2L V6 equipped models with VIN numbers from '98 start of production to W , refer to bulletin number SB98-04-L002 (Service Campaign 9804L2).. If campaign 9804L2 applies to the subject vehicle, then inspect the vehicle for a campaign completion label (One or more campaign labels may exist) for campaign 9804L2. (The ICS system may be referenced for detailed campaign status information regarding the subject vehicle.). If the vehicle is affected by Service Campaign 9804L2 and the repair has not been performed, then it is recommended that Service Campaign 9804L2 is completed prior to the installation of the Fuel Gauge Sender Service Kit. (Refer to SB98-04-L002) 1. Record any radio station presets and disconnect the negative terminal of the battery. 2. Remove the fuel tank assembly from the vehicle. (Refer to Workshop Manual) Important: The (Green) retaining clips of the fuel lines leading to the fuel pump assembly may break with excessive force. Take special caution when handling this clip. The retaining clips are not included in the repair kit and would have to be ordered separately, if breakage has occurred and replacement is needed. (Refer to Parts Information) 3. Remove the snap ring and remove the Fuel Pump and Sender (FPAS) assembly from the fuel tank. Note: After removing the FPAS assembly, cover the fuel tank to prevent any debris from entering. 4. Remove the float arm from the original sending unit.. Using a small screwdriver, carefully pry the float arm pivot (near the brass bushing) from the sending unit. (Figure 1)

Figure 1 Important: Do not allow any portion of the float arm to bend.

A deformed float arm will result in inoperative sending unit. 5.

2 Figure 1 Important: Do not allow any portion of the float arm to bend. Be sure the 90 bend near the pivot of the float arm is intact. A deformed float arm will result in inoperative sending unit. 5. Disconnect the (Blue/Black) harness connection from the fuel pump assembly (Figure 2). Figure 2 6. Remove the (Attention) locking clip and disconnect the harness connection from the top of the FPAS housing. (Figure 3). Figure 3 7. Remove the (Black) locking clip and remove the sending unit from the FPAS housing.

(Figure 4) Figure 4 8. Replace the O-ring at the top of the FPAS housing.

Before installing new sending unit, locate the electrical connector at the top of the fuel

The service kit includes two sending units, each with the proper termination necessary for the

3 (Figure 4) Figure 4 8. Replace the O-ring at the top of the FPAS housing. (Figure 5) Figure 5 9. Before installing new sending unit, locate the electrical connector at the top of the fuel pump (near the center of the FPAS housing). This connector is either a small or large type. The service kit includes two sending units, each with the proper termination necessary for the two types of fuel pump connectors currently in existence. Use only one sending unit with harness, which will properly connect to the fuel pump. Discard the other sending unit. (Figure 6) Figure 6

10. Install new sending unit to the FPAS housing.

Reconnect the (Blue/Black) harness connection to the fuel pump

4 10. Install new sending unit to the FPAS housing. (Figure 7) Figure Reinstall the (Black) locking clip to the FPAS housing. (Figure 8) Figure Reconnect the (Blue/Black) harness connection to the fuel pump assembly. (As shown in Figure 2 and Figure 6) 13. Reconnect the harness at the top of the FPAS housing and reinsert the (Attention) locking clip to the harness connector. (Figure 9) Figure 9

14. Reinstall the original float arm to the new sending unit. (Figure 10) Important: Do not allow any portion of the float arm to bend. Be sure the 90 bend near the pivot of the float arm is intact.

5 14. Reinstall the original float arm to the new sending unit. (Figure 10) Important: Do not allow any portion of the float arm to bend. Be sure the 90 bend near the pivot of the float arm is intact. A deformed float arm will result in inoperative sending unit. Raise and lower the float to ensure that no binding exists. Figure 10 Parts Information 15. Reinstall the FPAS assembly to the fuel tank. (Refer to Workshop Manual) Important: Before installation of the FPAS, make sure that the (clear) fuel delivery hose from the fuel pump is fully inserted to its connections and not kinked or pinched during the installation into the fuel tank. 16. Reinstall the fuel tank to the vehicle. (Refer to Workshop Manual) Important: The (Green) retaining clips of the fuel lines leading to the fuel pump assembly may break with excessive force. Apply a light coat of engine oil to the fuel line fittings before reconnecting. 17. Perform PCM recalibration using the Isuzu Technical Communication System (ITCS) and CD#13 (or later) with the TECH 2 to download the appropriate "Fuel Gauge" calibration. (Refer to Attachment "A") Note: The use of the "Fuel Gauge" calibration must be accompanied by the installation of the new sending unit. If the application chart is not followed, inoperative fuel gauge will result. 18. Reconnect the battery and reset the radio presets and the clock. 19. Start the vehicle and confirm proper operation.. Check for any fuel leaks. Ensure that all lines are properly reconnected.. Ensure that the fuel gauge, radio, and clock are fully functional. Part Number Description Quantity Required (Rodeo Only) (Amigo Only) Fuel Gauge Sender Service Kit Includes: 2 Upgraded Sending Units (large/small conn.) O-ring (for FPAS installation) Retaining Clips (Attention, Black) Retainer; Fuel Tube (5/16) * 1 Kit

6 Retainer; Fuel Tube (3/8) * * Replacement Fuel Tube Retainers (green-colored clip) may be required in isolated cases where breakage has occurred during removal or installation of the fuel line. Warranty Claim Information Use the following new labor operation: Operation Operation No. Task Time Additional Instructions Fuel Gauge Sender Service Kit Install 1.5 Includes: Fuel tank and FPAS R&R PCM reprogramming Labor time includes administrative time allowance. Attachment A Fuel Gauge Sending Unit And Calibration Applications For 3.2L V6 Models: 1. Select updated Fuel Gauge Sending Unit: P/N (98 UE only) P/N (98 UA only) 2. Install Fuel Gauge Sending Unit per installation procedure in this TSB. 3. Select new PCM Calibration from the following: CSMM (UE/UA 3.2L V6 FED M/T) CSMN (UE 3.2L V6 FED A/T) CSMP (UE/UA 3.2L V6 CALF M/T) CSMR (UE 3.2L V6 CALF A/T) 4. Calibrate the PCM with new calibration. Note: All Fuel Gauge Sending unit calibrations used in this TSB include the calibration update for the Battery Discharge Service Campaign # 9804L2 For 2.2L 4 Cylinder Models: 1. Select updated Fuel Gauge Sending Unit: P/N (98 UE only) P/N (98 UA only) 2. Install Fuel Gauge Sending Unit per installation procedure in this TSB. 3. Select new PCM Calibration from the following:

7 CSWM (UE/UA 2.2L 4 Cylinder FED M/T) CSWN (UE/UA 2.2L 4 Cylinder CALF M/T) 4. Calibrate the PCM with new calibration. This Service Bulletin is intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others and damage to your vehicle that may cause it not to operate properly Copyright Isuzu Motors America, Inc. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, photocopying, recording, or otherwise), without prior written permission of Isuzu Motors America, Inc

THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE.

THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. NUMBER: 14-002-01 GROUP: Fuel DATE: Mar. 16, 2001 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in