Fuel Level Sensor: Removal
- Disconnect negative battery cable. Loosen fuel filler cap. Install Fuel Pressure Gauge (J-34730-1A) to fuel pressure test head. Wrap shop towel around pressure connection when installing fuel pressure gauge to absorb fuel leakage. Place gauge bleed hose in container. Open bleed valve to relieve fuel pressure.
- Remove fuel cap. Install Fuel Flapper Door Holder (J-42960-2) into fuel fill pipe in order to hold fuel door open. Install Fuel Drain Hose (J-42960) into fuel tank until hose reaches bottom of fuel tank. Using an air operated pump device, drain as much fuel through fuel fill pipe as possible.
- Raise and support vehicle. Disconnect quick-connect fitting at inlet side of fuel filter. Disconnect quick-connect fitting on fuel return pipe, near fuel filter. Disconnect Evaporative Emission (EVAP) purge pipe quick-connect fitting at EVAP canister. Disconnect vapor recirculation pipe from filler tube.
- With aid of an assistant, support fuel tank. Remove fuel tank strap attaching bolts. Disconnect fuel sender and fuel tank pressure sensor harness connectors at body pass through. Remove fuel tank from vehicle.
- Clean all fuel pipe connections, hose connections and areas surrounding connections before disconnecting connections, in order to avoid possible contamination of fuel system. Disconnect quick-connect fittings at fuel sender assembly.
- Remove fuel sender assembly and seal from fuel tank. Discard fuel sender assembly seal. Clean fuel sender assembly sealing surfaces. Remove fuel level sensor from fuel sender assembly.
CAUTION:
DO NOT handle fuel sender assembly by fuel pipes. Amount of leverage generated by handling fuel pipes could damage joints.
CAUTION:
Drain fuel from fuel sender assembly into an approved container in order to reduce risk of fire and personal injury. Never store fuel in an open container.