How do you replace fuel level sending unit on 2001 rodeo?

Answer 1

This is an easy 2 hour job, that unfortunately on the Rodeos needs to be done about every 60K miles.

1) use as much fuel from the gas tank as possible, an empty tank is easier to work with

2) remove the spare tire

3) disconnect: fuel line (2 line setup- send and return), fill line, vent lines

4) brace the gas tank, and remove the 4-6 bolts that hold it on

5) lower the tank, clean the outside of the fuel pump off, you don't want dirt getting into the tank when you pull out the fuel pump

6) remove the fuel pump, this is harder than it looks- you may need to use screw drivers to pry it out, try your best to not break it.

7) replace the sending unit, make sure to plug the correct plug in, I plugged them in wrong the first time and ended up doing this job twice.

8) To check the sending unit, you can plug in the electrical connections and turn on the ignition (don't start the engine), the sending unit sends fuel as soon as the ignition is turned on, you can check the fuel by having the fuel filter off and if you get fuel flowing from the line then you have it plugged in properly.

9) replace everything the way it came apart, I would also replace the fuel filter while you have the truck apart. Also, think about the position of the fuel lines when you replace the ring that holds the fuel pump in place, if you tighten the ring too much the lines won't be able to reconnect, so plan for the lines on the fuel pump to move as you tighten the ring back into place.