Fuel Level Sensor: Service and Repair

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 34730 Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

CAUTION:
^ Refer to Actions to take when Working With Fuel in Service and Precautions.
^ Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.
^ Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

NOTE:
^ Refer to Clean All Connections In Order to Avoid Contamination in Service and Precautions.
^ Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair




2. Drain the fuel tank (1) to at least 3/4 of a tank full. Refer to Fuel Tank Draining Procedure. Procedures

IMPORTANT: The modular fuel sender support assembly will spring-up when the locking ring is moved.




3. Remove the fuel sender assembly.

DISASSEMBLE PROCEDURE




1. Note the position of the fuel sender strainer for installation.
2. Support the reservoir with one hand and grasp the fuel sender strainer with the other hand.
3. Pull the external fuel sender strainer off of the fuel pump.
4. Inspect the fuel sender strainer. If the fuel sender strainer is contaminated, the fuel tank should be cleaned.
5. Discard the fuel sender strainer after inspection.




6. Disassemble the electrical connectors from the sensor assembly of the fuel pump and the cover assembly.
7. Disassemble the fuel level sensor assembly.

ASSEMBLE PROCEDURE




1. Assemble the fuel level sensor assembly.
2. Assemble the electrical connectors to the fuel pump and the cover assembly.




3. Position the new fuel sender strainer on the modular fuel sender and push on the outer edge of the fuel sender strainer until the fuel sender strainer is fully seated.

INSTALLATION PROCEDURE




1. Reinstall the fuel sender assembly.

CAUTION: Refer to Battery Disconnect Caution in Service and Precautions.

2. Connect the negative battery cable.
3. Inspect for leaks.
3.1. Turn ON the ignition for 2 seconds.
3.2. Turn OFF the ignition for 10 seconds.
3.3. Turn ON the ignition.
3.4. Check for fuel leaks.

NOTE: Refer to Fastener Notice in Service and Precautions.




4. Install the fuel sender access panel (2).

Tighten
Tighten the fuel sender access panel bolts to 2 N.m (18 lb in).

5. Install the rear compartment floor trim (1).
6. Install the spare tire, the jack, and the spare tire cover.




7. Add fuel to the fuel tank.
8. Install the fuel tank filler pipe cap (1).
9. Install the rear seat cushion.




10. Install the intake manifold sight shield (1) to the engine.
11. Install the intake manifold sight shield nuts (2).

Tighten
Tighten the nuts to 3 N.m (27 lb in).