Fuel Level Sensor

FUEL LEVEL SENSOR

Part 1:

Part 2:

Part 1:

Part 2:

Exploded View

Special Tool(s):

Special Tool(s)

Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- 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 components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- This procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.

1. Release the fuel system pressure.
2. Disconnect the battery ground cable.







3. Release the fuel tank filler cap and position aside.







4. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet tube.

5. CAUTION: The fuel pump (FP) module and fuel level sensor will be below the fuel level in the tank when the tank is full. Make sure to drain 1/8 of the fuel capacity through the filler pipe prior to removing the FP module or fuel spillage will occur.

NOTE: When draining a completely full fuel tank, this step will remove approximately 1/8 of fuel from the LH side of the fuel tank.

Attach the fuel storage tanker to a suitable fuel drain tube and remove as much fuel as possible from the fuel tank filler pipe.

6. Remove the rear seat cushion.
7. Position any insulation padding covering the FP module and fuel level sensor access covers aside.







8. Remove the FP module and fuel level sensor access covers and position aside.







9. Disconnect the FP module electrical connector.







10. NOTE: Place absorbent pads in the general work area in case of fuel spillage.

Disconnect the rear fuel supply tube-to-FP module quick connect coupling.







11. Using the special tool, remove and discard the FP module retaining lock ring.







12. Position the FP module aside. Using the fuel storage tanker and a suitable fuel drain tube, completely drain the remaining fuel from the LH side of the fuel tank.

13. NOTE: Draining the remainder of the fuel in the RH side of the fuel tank should be done immediately to prevent siphoning of the fuel back into the LH side of the fuel tank.

Carefully lift the FP module out of the fuel tank enough to allow access to the crossover fuel tube-to-FP module quick connect coupling.







14. Disconnect the crossover fuel tube-to-FP module quick connect coupling.







15. Insert a suitable fuel drain tube into the crossover fuel tube quick connect coupling.
16. Attach the fuel storage tanker to the suitable fuel drain tube and completely drain the remainder of the fuel from the RH side of the fuel tank.
17. Remove and discard the FP module O-ring seal.







18. Disconnect the fuel level sensor electrical connector.







19. Using the special tool, remove and discard the fuel level sensor retaining lock ring.
20. Carefully lift the fuel level sensor out of the fuel tank enough to allow access to the crossover fuel tube-to-fuel level sensor quick connect coupling.







21. Disconnect the crossover fuel tube-to-fuel level sensor quick connect coupling.
22. Completely remove the fuel level sensor from the fuel tank.
23. Remove and discard the fuel level sensor O-ring seal.

Installation

1. CAUTION:
- Inspect the surfaces of the fuel level sensor mounting flange and the fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring contact area of the fuel tank flange or the fuel tank. Install a new fuel level sensor or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
- Make sure to install a new fuel level sensor O-ring seal and lock ring.

NOTE:
- Prior to installing the fuel level sensor and O-ring seal, thoroughly clean any contaminants from fuel level sensor and fuel tank mounting flanges.
- Upon installation, apply clean engine oil to the O-ring seal.

Install the new fuel level sensor O-ring seal.

2. Position the fuel level sensor into the fuel tank.







3. Connect the crossover fuel tube-to fuel level sensor quick connect coupling.







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

Using the special tool, install the new fuel level sensor retaining lock ring.
- Tighten the lock ring until it meets the stops on the fuel tank.







5. Connect the fuel level sensor electrical connector.

6. CAUTION:
- Make sure to install a new FP module O-ring seal and lock ring.
- Inspect the surfaces of the FP module mounting flange and the fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE:
- Prior to installing the FP module and O-ring seal, thoroughly clean any contaminants from FP module and fuel tank mounting flanges.
- Upon installation, apply clean engine oil to the O-ring seal.

Install the new FP module O-ring seal.

7. Position the FP module into the fuel tank.







8. Connect the crossover fuel tube-to- the FP module quick connect coupling.

9. NOTE: Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring.

Using the special tool, install the new FP module retaining lock ring.
- Tighten the lock ring until it meets the stops on the fuel tank.







10. Connect the rear fuel supply tube-to-FP module quick connect coupling.







11. Connect the FP module electrical connector.







12. NOTE: Remove and discard the absorbent pads.

Install the FP module and the fuel level sensor access covers.

13. Install any insulation padding covering the FP module and fuel level sensor access covers.
14. Install the rear seat cushion.
15. Using the fuel storage tanker, refuel the fuel tank.







16. Install the fuel tank filler cap.
17. Connect the battery ground cable.

18. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system.

Check for leaks before starting the engine.

19. Start the engine and check for leaks.