Fuel Level Sensor: Service and Repair

REMOVAL PROCEDURE

CAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank).
4. Remove the fuel tank.




5. Remove the fuel sender assembly.




6. Disconnect the fuel pump electrical connector (5).
7. Remove the retaining clip (6) from the fuel level sensor connector.
8. Disconnect the electrical connector (7) from under the fuel sender cover.
9. Remove the sensor retaining clip (4).
10. Squeeze the locking tangs and remove the fuel level sensor (3).

INSTALLATION PROCEDURE




1. Install the fuel level sensor (3).
2. Install the sensor retaining clip (4).
3. Connect the electrical connector (7) to the fuel level sensor.
4. Connect the retaining clip (6) to the fuel level sensor electrical connector.
5. Connect the fuel pump electrical connector (5).




6. Install the fuel sender assembly.




7. Install the fuel tank.
8. Refill the fuel tank.
9. Install the fuel filler cap.
10. Connect the negative battery cable.
11. Inspect for leaks.
11.1. Turn the ignition ON for 2 seconds.
11.2. Turn the ignition OFF for 10 seconds.
11.3. Turn the ignition ON.
11.4. Inspect for fuel leaks.