Fuel Level Sensor - Steel Fuel Tank

Fuel Level Sensor - Steel Fuel Tank

NOTE: Aft-of-axle fuel tank shown, auxiliary fuel tank similar.

NOTE: This procedure is for diesel applications only.











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: 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.

NOTE: This procedure is for diesel applications only.

1. NOTE: The fuel tank must be drained completely. Upon removal of the fuel level sensor, the tank must be inspected for contamination.

Remove the fuel tank. For additional information, refer to Fuel Tank - Aft-of-Axle Fuel Tank - Aft-Of-Axle or Fuel Tank - Auxiliary Fuel Tank - Auxiliary.

2. NOTICE: Clean the fuel tank of any dirt or foreign material before servicing the fuel level sensor. In extreme dirt or dusty conditions it may be necessary to wash the fuel tank using a water hose. Before removing the fuel level sensor, make sure that there is no residual dirt or foreign material around the fuel level sensor flange. If dirt or foreign material enter the fuel tank, damage to the fuel level sensor or other fuel system components may occur.

Clean the area around the fuel level sensor mounting flange.

3. NOTE: Mark the orientation of the fuel level sensor on the fuel tank to aid in installation.

Remove the 6 bolts from the fuel level sensor.

- To install, tighten to 10 Nm (89 lb-in).

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

Completely remove the fuel level sensor from the fuel tank.

5. NOTE: Inspect the surfaces of the fuel level sensor flange and fuel tank gasket contact surfaces. Do not polish or adjust the gasket contact area of the fuel tank flange or the fuel tank. Install a new fuel level sensor or fuel tank if the gasket contact area is bent, scratched or corroded or fuel leakage could occur causing vehicle damage.

NOTE: Make sure to install a new fuel level sensor gasket or fuel leakage could occur causing vehicle damage.

Remove and discard the fuel level sensor gasket.

6. To install, reverse the removal procedure.
- Make sure the fuel level sensor is installed in the same orientation as the original.