Fuel Level Sensor

FUEL LEVEL SENSOR

Front Wheel Drive (FWD) Vehicle (Part 1):

Front Wheel Drive (FWD) Vehicle (Part 2):

All Wheel Drive (AWD) Vehicle (Part 1):

All Wheel Drive (AWD) Vehicle (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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may 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 may 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 spout.

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 fuel level sensor or fuel spillage will occur.

Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel remaining in the fuel tank filler pipe.

6. Remove the rear seat.
7. Position the carpet and/or any insulation covering the fuel level sensor access cover aside.







8. Remove the 4 screws and the fuel level sensor access cover.







9. Disconnect the fuel level sensor electrical connector.







10. CAUTION: Place absorbant pads in the general work area in case of fuel spillage.

Release the lock tab, rotate the fuel level sensor counterclockwise approximately 1/4 turn and lift upward.

11. CAUTION:
- The fuel level sensor must be handled carefully to avoid damage to the float arm.
- 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.

12. CAUTION: 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:
- To install, apply clean engine oil to the O-ring seal.
- Upon installation, properly seat and press down firmly on the fuel level sensor, rotate it clockwise until the lock arrow on the sensor aligns with the notch on the tank. Torque should not exceed 15 Nm (11 lb-ft).

To install, reverse the removal procedure.