Fuel Level Sensor: Service and Repair

REMOVAL PROCEDURE





TOOLS REQUIRED
J 34730 Fuel Pressure Gauge

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





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 (1) 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.
2. Add fuel to the fuel tank.
3. Install the fuel tank filler pipe cap.
4. Connect the negative battery cable.
5. Reinstall the rear seat lower cushion.
5.1. Turn the ignition switch ON for 2 seconds.
5.2. Turn the ignition switch OFF for 10 seconds.
5.3. Turn the ignition switch ON.
5.4. Check for fuel leaks.
6. Reinstall the fuel injector sight shield.
7. Reinstall the compartment close out panel.