Fuel Level Sensor

Fuel Level Sensor





NOTE: This procedure is for diesel applications only. Aft tank shown others similar.









Removal

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: 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.

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.

NOTE: The fuel level sensor has a serviceable fuel level sender. For additional information, refer to Fuel Level Sender Fuel Level Sender.

1. NOTE: To avoid introducing contamination into the fuel tank use water to clean the fuel level sensor connections, couplings, flange surface and the immediate surrounding area of any dirt or foreign material. Blow dry thoroughly with shop air after cleaning.

Remove the fuel tank. For additional information, refer to Fuel Tank and Lines - Gasoline and Diesel Fuel Tank.

2. NOTICE: Carefully install the lock ring wrench to avoid damaging the fuel level sensor when removing the lock ring

Install the lock ring wrench and remove the fuel level sensor lock ring.





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

NOTE: The fuel level sensor will have residual fuel remaining internally, drain into a suitable container.

Carefully remove the fuel level sensor from the fuel tank.

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

5. Inspect the fuel level sensor for missing or broken components. Remove any missing or broken components from the fuel tank

Installation

1. NOTE: Inspect the mating surfaces of the fuel level sensor flange and the fuel tank O-ring seal contact surfaces. Wipe clean with a lint-free rag.

NOTE: Manually sweep the float arm to ensure freedom of travel.

Install a new fuel level sensor O-ring seal.

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

Install the fuel level sensor by inserting float rod through fuel tank opening first.

3. NOTICE: Carefully install the lock ring wrench to avoid damaging the fuel level sensor when installing the lock ring

NOTE: Install a new lock ring if it is bent, damaged or corroded

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

Install the lock ring wrench and tighten the fuel level sensor lock ring.





4. Install the fuel tank. For additional information, refer to Fuel Tank and Lines - Gasoline and Diesel Fuel Tank.