Fuel Level Sensor

Fuel Level Sensor









Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTE: The fuel level sensor has a serviceable fuel level sender. For additional information, refer to Fuel Level Sender Fuel Level Sender.

1. Release the fuel system pressure.

2. Disconnect the battery ground cable.

3. Remove the rear seat lower cushion.

4. Remove the Fuel Pump (FP) module access cover.

5. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.

Disconnect the FP module electrical connector.

6. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.

Disconnect the fuel tank jumper tube-to-FP module quick connect coupling.

7. Connect the Fuel Storage Tanker to the FP module fuel outlet fitting and remove approximately 1/4 of the fuel (from a completely full tank), lowering the fuel level below the fuel level sensor mounting flange.





8. Remove the fuel level sensor access cover.

9. NOTE: Clean the fuel level sensor connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.

Disconnect the fuel level sensor electrical connector.

10. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.

NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the fuel level sensor when removing the lock ring.

Install the Fuel Tank Sender Unit Wrench, remove and discard the fuel level sensor lock ring.





11. NOTE: The fuel level sensor must be handled carefully to avoid damage to the float arm.

Carefully lift the fuel level sensor out of the fuel tank allowing access and disconnect the internal fuel tube-to-fuel level sensor quick connect coupling.

12. Remove the fuel level sensor from the fuel tank.

13. NOTE: To install, apply clean engine oil to the O-ring seal.

Remove and discard the fuel level sensor O-ring seal.

14. NOTE: Make sure to install a new fuel level sensor lock ring and O-ring seal.

To install, reverse the removal procedure.

- Make sure the alignment arrows on the fuel level sensor and the fuel tank meet before tightening the fuel level sensor lock ring.

- Tighten the fuel level sensor lock ring until it meets the stop tabs on the fuel tank.