UPDATE....

Didn't work but it may have been me screwing up since I had an emergency rotor replacement, balancing and alignment to do at the same time..

This will probably turn into a here you go Mr. Stealership, enjoy your lobster lunch on me.

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You have won over some tougher problems than this ;) Keep at it and eat the lobster yourself! ;)

Reviving an old thread, sorry. Just replaced my fuel pump unit. The complete unit with the Delphi part. I didn't drain the tank and just put the new pump in. Drove it for awhile and went to do a fill up when it showed 1/4. Normally, I can pretty accurately calculate how much gas it's going to take by using the consumption value that I reset every time I fill up and divide the miles driven on the tank. It is usually pretty accurate, at 1/4 it should and typically does take 18 gallons (24 gallon tank approx.). This time I calculated I would need 20 gallons and it was correct, that's what it took. So, I've been watching it as I drive down this tank and it appears to be still reading too high. Someone mentioned above that it eventually settles down to being accurate? Is that correct or is recalibration necessary, and if so how do I do that? Not sure test 21 is the way and I haven't been able to find anything other than correcting for consumption error.

Well mine (the 1st time) settled down and was perfect, but the 2nd time never would and even #21 didn't fix it. I have been unable to source the rheostat (?) plates new in Kingdom so until then I am basically doing backwards birth control, I pull in every time I get close.... [emoji1787]

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Dang, making me decide between a full assembly or pump only replacement. X5 is almost approaching 165k miles. Runs great but I know the pump can go at anytime.

That's why I replaced mine it had at least 130,000 miles on it.

I saved the old unit. If I can't get this figured out I may pull the old pump out of it and pull the new pump out of the new unit and put it in the old carrier and put that back into the tank. The other option I'm considering is bending the float rod a little so it reads right. I have to think about that one for awhile though.

No!! Don't bend the float rod.

It can lead to needing new rheostat plates!!

Not that I would even try such a thing....[emoji849][emoji28]

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+1, do NOT bend the float. 1/4 tank is right around where the two sides go separate so probably the worst place to try to judge gauge accuracy, plus the non fuel pump side sender is responsible for most of the fuel at that point anyway.

Thanks guys. I'll leave that float rod alone.