Fuel Level Sensor

Fuel Level Sensor









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: Do not carry personal electronic devices such as cell phones, pagers or audio equipment 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: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction 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.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.

2. Disconnect the battery ground cable. For additional information, refer to Battery.

3. Remove the rear seat lower cushion. For additional information, refer to Seats.

4. Remove the Fuel Pump (FP) module access cover.

5. Disconnect the fuel tank jumper tube-to-FP module quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.

6. Attach the Fuel Storage Tanker tube to the FP module outlet fitting and remove one fourth (approximately 5 gallons) of the fuel from a completely full tank, lowering the fuel level below the fuel level sensor flange.





7. Remove the fuel level sensor access cover.

8. NOTE: Clean the fuel level sensor connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.

Disconnect the fuel level sensor electrical connector.

9. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.

NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the fuel level sensor when removing the lock ring.

Install the Fuel Tank Sender Unit Wrench, remove and discard the fuel level sensor lock ring.





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

Carefully lift the fuel level sensor out of the fuel tank allowing access and disconnect the quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.

11. Remove the fuel level sensor from the fuel tank.

12. NOTE: During installation, apply clean engine oil to the O-ring seal.

Remove and discard the fuel level sensor O-ring seal.

13. NOTE: Make sure to install a new fuel level sensor O-ring seal.

To install, reverse the removal procedure.

- Make sure the alignment arrows on the fuel level sensor and the fuel tank meet before tightening the fuel level sensor lock ring.

- Tighten the fuel level sensor lock ring until it meets the stop tabs on the fuel tank.