1998 RODEO (UE)/AMIGO (UA) FUEL GAUGE INACCURACY

1998 RODEO (UE)/AMIGO (UA) FUEL GAUGE INACCURACY (SUPERCEDES

SB97-02-L009)

SERVICE CAMPAIGN BULLETIN

Reference Number(s): TSB SB98-02-L002, Date of Issue: NOVEMBER, 1998

ISUZU: 1998 Rodeo (UE) and Amigo (UA)

APPLIES TO:SEE AFFECTED VEHICLES

Superceded Bulletin(s): SB97-02-L009, Date of Issue:

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 W4334228, 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 )

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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.

1. Using a small screwdriver, carefully pry the float arm pivot (near the brass

bushing) from the sending unit. (Fig 1 )

Fig 1: Prying Float Arm Pivot From Sending Unit



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 (Fig 2 ).

Fig 2: Disconnecting Harness Connection From Fuel Pump Assembly

6. Remove the (Attention) locking clip and disconnect the harness connection from the top

of the FPAS housing. (Fig 3 ).



Fig 3: Removing Locking Clip

7. Remove the (Black) locking clip and remove the sending unit from the FPAS housing.

(Fig 4 )



Fig 4: Removing (Black) Locking Clip

8. Replace the O-ring at the top of the FPAS housing. (Fig 5 )



Fig 5: Replacing O-Ring At Top Of FPAS Housing

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. (Fig 6 )



Fig 6: Identifying Small And Large Connector

10. Install new sending unit to the FPAS housing. (Fig 7 )



Fig 7: Installing Sending Unit To FPAS Housing

11. Reinstall the (Black) locking clip to the FPAS housing. (Fig 8 )



Fig 8: Installing (Black) Locking Clip To FPAS Housing

12. Reconnect the (Blue/Black) harness connection to the fuel pump assembly. (As shown

in Fig 2 and Fig 6 )

13. Reconnect the harness at the top of the FPAS housing and reinsert the (Attention)

locking clip to the harness connector. (Fig 9 )



Fig 9: Inserting (Attention) Locking Clip To Harness Connector

14. Reinstall the original float arm to the new sending unit. (Fig 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.



Fig 10: Installing Original Float Arm To New Sending Unit

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.

1. Check for any fuel leaks. Ensure that all lines are properly reconnected.

2. Ensure that the fuel gauge, radio, and clock are fully functional.

Parts Information

PARTS INFORMATION DESCRIPTION

Part

Number Description

Quantity

Required

8-25323-

011-0

(Rodeo

Only)

8-25323-

012-0

(Amigo

Only)

Fuel Gauge Sender Service Kit Includes:

2 Upgraded Sending Units (large/small conn.) O-ring (for FPAS

installation) Retaining Clips (Attention, Black)

1 Kit

2-90442-

800-0

Retainer; Fuel Tube (5/16)

2-90442-

810-0

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:

WARRANTY CLAIM INFORMATION

Operation

Operation

No. Task Time Additional Instructions

Fuel Gauge Sender

Service Kit

020392 Install 1.5 Includes: Fuel tank and FPAS R&R PCM

reprogramming

(1)

(1)

(1)



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:

Fig 11: Identifying Fuel Gauge Sending Unit

2. Install Fuel Gauge Sending Unit per installation procedure in this TSB.

3. Select new PCM Calibration from the following:



Fig 12: Identifying PCM Calibration Application

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:

Fig 13: Identifying Fuel Gauge Sending Unit



2. Install Fuel Gauge Sending Unit per installation procedure in this TSB.

3. Select new PCM Calibration from the following:

Fig 14: Identifying PCM Calibration Application

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.



Documents

1998 RODEO (UE)/AMIGO (UA) FUEL GAUGE INACCURACY