Fuel Level Sensor: Service and Repair

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J34730-1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. Service and Repair
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. Procedures
3. Remove the fuel tank.
4. Remove the fuel sender assembly.
5. Remove the fuel pump and fuel level sender electrical retaining clip at the top of the modular fuel sender assembly.
6. Disconnect the fuel pump and fuel level sender electrical connector.
7. Depress the 3 tabs securing the upper fuel reservoir and slide upward until free of the lower reservoir.
8. Depress the tab on the fuel level sensor while sliding up and out of the housing.
9. Remove the retaining clip from the electrical connector.
10. Remove the fuel level sender wires from the connector, taking care to note the location of the wires.

INSTALLATION PROCEDURE

IMPORTANT:
^ Make sure the wires are routed under the fuel level sender.
^ Make sure the tab locks in place.

1. Install the fuel level sensor by sliding the sensor down into the housing.
2. Slide the upper reservoir into the lower reservoir.
3. Connect the 2 wires into the connector and lock with the retaining clip.
4. Connect the fuel pump and fuel level sensor electrical connector and lock with the retaining clip.
5. Reinstall the fuel sender assembly.
6. Reinstall the fuel tank.
7. Refill the fuel tank.
8. Reinstall the fuel fill cap.
9. Connect the negative battery cable.
10. Inspect for leaks using the following procedure:
10.1. Turn ON the ignition for 2 seconds.
10.2. Turn OFF the ignition for 10 seconds.
10.3. Turn ON the ignition.
10.4. Inspect for fuel leaks.