Fuel Level Sensor: Service and Repair

REMOVAL PROCEDURE

CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair
2. Drain the fuel tank (1). Refer to Fuel Tank Draining Procedure. Procedures
3. Remove the fuel sender assembly.

DISASSEMBLE PROCEDURE




1. Note the position of the fuel strainer (1) for installation.
2. Support the reservoir with one hand and grasp the fuel strainer with the other hand.
3. Place the fuel sender assembly upside down on a bench.
4. Remove the fuel sender strainer.
5. Inspect the fuel sender strainer. If the strainer is contaminated, the fuel tank should be cleaned. Refer to Fuel System Cleaning. Discard the fuel level sensor after inspection.




6. Disconnect the electrical connectors from the fuel pump and cover assembly.
7. Remove the fuel level sensor assembly.

ASSEMBLE PROCEDURE

IMPORTANT: Always install a new fuel level strainer when installing a fuel sender or a fuel level sensor assembly.




1. Position the new fuel sender strainer (1) on the fuel sender. Push the outer edge of the strainer until the strainer is fully seated.




2. Install the new fuel level sensor assembly.
3. Connect the electrical connectors to the fuel pump and the cover assembly.

INSTALLATION PROCEDURE

NOTE: Refer to Fastener Notice in Service Precautions.




1. Install the fuel sender assembly.
2. Add fuel to the fuel tank.
3. Install the fuel filler cap.
4. Connect the negative battery cable.
5. Inspect for leaks.
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.