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.

1. Release the fuel system pressure.

2. Disconnect the battery ground cable.

3. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.

4. NOTICE: When removing the Fuel Draining Hose, the fitting on the end of the hose can become detained by the safety valve. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.

NOTE: The Fuel Draining Hose must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank, opening the safety valve.

Insert the Fuel Draining Hose into the fuel tank filler pipe.





5. NOTE: This step will remove approximately one-eighth tank of the fuel from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe.

Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove approximately one-eighth tank of fuel (from a completely full tank), lowering the fuel level below the fuel level sensor mounting flange.

6. Remove the rear seat lower cushion.

7. Remove the 3 screws and the fuel level sensor access cover.
- To install, tighten to 2 Nm (18 lb-in).

8. Disconnect the fuel level sensor electrical connector.

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

Release the lock tab, rotate the fuel level sensor counterclockwise approximately one-fourth turn and lift upward.





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

NOTE: Carefully remove the fuel level sensor from the fuel tank to avoid fuel spillage inside the vehicle.

Carefully lift and remove the fuel level sensor from the fuel tank.

11. NOTICE: Inspect the mating surfaces of the fuel level sensor flange and the fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal 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.

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

NOTE: To install, apply clean engine oil to the new O-ring seal.

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

12. To install, reverse the removal procedure.
- Make sure the fuel level sensor locking tab is correctly positioned.