Fuel Level Sensor

FUEL LEVEL SENSOR

Exploded View

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

All Wheel Drive (AWD) Vehicle (Part 2):

Special Tool(s)

Special Tool(s):

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.
- 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.
- 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. Release the fuel tank filler cap and position aside.
3. Insert a suitable fuel drain tube into the fuel tank filler pipe until it enters the fuel tank.







4. NOTE: If the fuel tank is completely full, this step will lower the fuel level below the fuel level sensor mounting flange.

Attach the fuel storage tanker to the fuel drain tube and drain approximately 1/8 of the fuel from the tank.

5. Remove the rear seat.
6. Remove the 4 bolts and the fuel level sensor access cover.

7. NOTE: Clean the fuel level sensor connection, flange surface and the immediate surrounding area of any dirt or foreign material.

Disconnect the fuel level sensor electrical connector.

8. NOTE: Place absorbant pads in the general work area in case of fuel spillage.

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







9. 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.

10. NOTE:
- 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.
- To install, apply clean engine oil to the O-ring seal.
- Upon installation, correctly 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.