Fuel Level Sensor: Service and Repair

REMOVAL PROCEDURE

CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.




1. Relieve the fuel system fuel pressure.




2. Drain the fuel tank.
3. Remove the fuel sender assembly.

DISASSEMBLE PROCEDURE




1. Inspect the position of the fuel strainer (1) for installation.
2. Support the reservoir with one hand and grasp the fuel strainer with the other hand.
3. Place the fuel sender assembly upside down on a bench.
4. Remove the fuel sender strainer.
5. Inspect the fuel sender strainer. If the fuel sender strainer is contaminated, the fuel tank should be cleaned. Discard the fuel level sensor after inspection.




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

ASSEMBLE PROCEDURE

IMPORTANT: Always install a new fuel level strainer (1) when installing a fuel sender or fuel level sensor assembly.




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




2. Install the new fuel level sensor assembly.
3. Install the electrical connectors to the fuel pump and the cover assembly.

INSTALLATION PROCEDURE

NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




1. Install the fuel sender assembly.
2. Add fuel and install the fuel tank filler pipe cap.
3. Install the negative battery cable.
4. Inspect for leaks.
4.1. Turn the ignition switch On for 2 seconds.
4.2. Turn the ignition switch Off for 10 seconds.
4.3. Turn the ignition switch On.
4.4. Check for fuel leaks.