Fuel Level Sensor

Special Tool(s)

Wrench, Fuel Tank Sender Unit 310-123

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.

 WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Remove the fuel tank. For additional information, refer to Fuel Tank in this section.

2. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.

   NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the fuel level sensor when removing the lock ring.

   Using the Fuel Tank Sender Unit Wrench, remove the fuel level sensor lock ring.

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

   Carefully lift the fuel level sensor out of the fuel tank allowing access and disconnect the internal fuel tube-to-fuel level sensor quick connect coupling. For additional information, refer to Section 310-00 .

4. NOTE: Some residual fuel may remain in the fuel level sensor. Carefully drain into a suitable container.

   Remove the fuel level sensor from the fuel tank.

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

6. NOTE: Install a new fuel level sensor O-ring seal.

   To install, reverse the removal procedure.
   • Make sure the alignment arrows on the fuel level sensor and the fuel tank meet before tightening the fuel level sensor lock ring.
   • Tighten the fuel level sensor lock ring until it meets the stop tabs on the fuel tank.