Warning!!! You should not do this mod if you are not comfortable working with/around a gas tank/gas fumes, please let a professional do it for you instead. Idea originally was done by Slader and I'd like to thank him for e-mailing me the information needed to do this project. Also this is not an inexpensive mod with current prices for parts, I just happened to have picked up the parts quite a while ago, but just got around to installing it. With that being said this mod will work for any '93-'94 U.S. Sol model without the low fuel lamp installed from the factory.
Please remember no smoking while doing this
project!!
Tools needed:
Phillips Screwdriver
Parts needed:
Bulb, low fuel : 78180-SH2-902
4-Unplug wiring from tank, for both sending and fuel pump and then start
unwrapping electrical wrap that goes to the float sending unit to the
cover, unwrap some on the topside of the cover too (Refer to picture
#1).
8-Attach/splice wire end for the dash wiring and the wire you just ran
from the sending unit at this time, it plugs into cavity #5, #4 and #5
will be empty cavities on the harness (right side plug for dash wiring).
9-Cut a hole out in back of dash unit with modeling knife for bulb (see
above picture), scrape off till you can see it looks shine like the
others that the bulbs fit into, install new bulb (you can remove the
blue cap if you want).
13-With the testing done it's not time to replace the float assembly.
First you may have to scrape some tar type material off the retaining
ring so it can move more easily. Using a hammer and a brass drift (so it
won't cause a spark), remove it by hitting it on the tabs sticking up
near the plug-in on the float (see pictures #1 for more on this, don't
use the tabs at the bottom), it may take a while but it will break loose
and start turning. By: GEO
Wire crimpers
Hammer
Brass drift
Meter assembly, fuel/temp '96'97 : 78130-SR2-A00ZA
Meter unit fuel (float) '95-'97 : 37800-SR2003
Wire end (off a used fuel sending unit, 6-12 inches of wire with plug-in
clip)
Wire end (off a used Sol cluster, 6-12 inches with plug-in clip)
Some wire connectors
Wire 14 gauge (about 6-8 feet)
Instructions:
1-You can start with removing the rear center panel, storage boxes and
center console.
2-Remove the dash cluster and unplug wire harness, then lay aside.
3-Remove cover for gas tank wiring by removing four phillips screws.
5-Attach/plug-in the wire pigtail end you picked up for the sending unit
into the cavity on the left-hand side of the plug, attach/splice the 14
gauge wire together with the pig-tail, run wire through cover and out
the top.
6-Rewrap the wires under cover and the top side that was take off
earlier.
7-Now you can run wire up the console area and out to the gauge area,
you can use wire ties if running it along side the wiring already there
to hold it in place.
10-Dissassemble gauge unit to install new fuel/temp gauge (remove the
six screws that form a triangle ( three each) at the bottom and top),
install new gauge unit.
11-Plug all wiring back in, but don't screw dash unit in at this time.
12-Plug fuel float wiring back into new float, turn on key, the low fuel
lamp should come on, also move float up and down to make sure the gauge
is working (remember it takes some time for the needle to move). If not
check your wiring and test again.
14-After it is loose you may want to use an air hose to blow any debris
out so it doesn't fall into the gas tank.
15- Now it's time to install the new float assembly, remove the old one
and replace it with the new one, then put the retaining ring back on and
tighten it back in the same matter you removed it.
16-Plug in the wiring for the float and put the cover back on with the
screws and replace the storage box, panel and center console and you
should be done.