Fuel Level Sensor: Service and Repair

Tools Required

J 34730 Fuel Pressure Gauge


REMOVAL PROCEDURE

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.

CAUTION: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

NOTICE: 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 Release / Service and Repair / Fuel Pressure Relief Procedure.

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

3. Remove the fuel tank. Refer to Fuel Tank Replacement.

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

4. Remove the fuel sender assembly. Refer to Refer to Fuel Tank Unit / Service and Repair / Fuel Sender Assembly Replacement.



DISASSEMBLE PROCEDURE






1. Note the position of the fuel sender strainer (2) 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 sender.

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 fuel level sensor assembly (3) of the fuel pump and cover assembly.

7. Disassemble the fuel level sensor assembly.


ASSEMBLE PROCEDURE

1. Assemble the fuel level sensor assembly (3).

2. Assemble the electrical connectors to the fuel pump and 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 on to the sender assembly.


INSTALLATION PROCEDURE






1. Install the fuel sender assembly into the fuel tank. Refer to Refer to Fuel Tank Unit / Service and Repair / Fuel Sender Assembly Replacement.

2. Install the fuel tank. Refer to Fuel Tank Replacement.

3. Lower the vehicle.

4. Install the negative battery cable.

5. Add fuel to the fuel tank.

6. Install the fuel tank filler pipe cap.

6.1. Turn ignition switch to ON for 2 seconds.

6.2. Turn the ignition switch to OFF for 5 seconds.

6.3. Turn the ignition switch ON.

6.4. Check for fuel leaks.