Procedure

1. Check for PCM DTCs. Refer to charts in the appropriate model year Powertrain Controls Service Manual for diagnosis.

2. Remove fuel tank from vehicle. Refer to "Fuel Tank" section of the appropriate model year Engine/Fuel/Air Intake/Exhaust Service Manual.

3. Drain any residual fuel from fuel tank.

4. Remove fuel pump module from fuel tank. Refer to "Fuel Pump Module" section of the appropriate model year Engine/Fuel/Air Intake/Exhaust Service Manual.





5. Measure float level by standing fuel pump module on a flat, horizontal surface and measure distance from this surface to bottom of float. A 4 mm (5/32 in.) diameter drill bit can be used as a gauge. The gauge must freely pass between float and horizontal surface with no more than 1.6 mm (1/16 in.) of clearance.

NOTICE:
If float arm requires repositioning to meet clearance specification, ensure that any bending is performed at 90 degree bend near fuel level sender. The short section of float arm going into fuel level sender must be supported to avoid bending the fuel level sender.

^ If float level is less than 4 mm (5/32 in.) adjust float level to 4 mm (5/32 in.).

^ If the float level was at 4 mm (5/32 in.) or greater, increase float level by 1.6 mm (1/16 in.).





6. Install fuel pump module into the fuel tank. Refer to the "Fuel Pump Module" section of the appropriate model year Engine/Fuel/Air Intake/Exhaust Service Manual.

7. Place fuel tank on a flat, horizontal surface and fill 1.5 gallons (5.7 L) of fuel in tank.





8. Using a DVOM and connector test adapter kit SA9206Z, measure resistance of fuel level sender at fuel pump module connector terminals "B" and "C" While measuring resistance, move tank to "slosh" fuel.

^ If resistance fluctuates between approximately 677 and 440 ohms, float level is correct and fuel tank can be reinstalled in vehicle. Refer to "Fuel Tank" section of the appropriate model year Engine/Fuel/Air Intake/Exhaust Service Manual.

^ If resistance remains at approximately 440 or fewer ohms, fuel pump module must be removed and float level increased by 1.6 mm (1/16 in.). Continue to increase float level by 1.6 mm (1/16 in.) increments until resistance fluctuates between approximately 677 and 440 ohms when fuel is "sloshed."

^ If resistance remains at 677 when the fuel is "sloshed," the float arm is adjusted too high as measured on the bench and must be adjusted back down.

9. After installing fuel tank in vehicle, verify that low fuel lamp illuminates with less than 1.5 gallons (5.7 L) of fuel in tank.