Fuel Level Sensor: Removal
- Release the fuel system pressure. Refer to: FUEL SYSTEM PRESSURE RELEASE .
- Disconnect the battery ground cable. Refer to: Battery Disconnect and Connect .
-
NOTE: The supplemental refueling adapter is located in the luggage compartment.
Install the supplemental refueling adapter and a 6 ft. length of 5/8 in. semi-rigid fuel drain tube into the Easy Fuel™ (capless) fuel tank filler pipe until the tube enters the fuel tank.
-
NOTE: This step is to remove approximately 3/16 tank of the fuel (3 gallons) from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the Fuel Pump and Sender Unit mounting flange.
Attach the Fuel Storage Tanker to the fuel drain tube and remove as much fuel as possible from the tank. Use Special Service Tool: 292-00004 Fuel Tanker 100 GPM.
- Remove the rear seat cushion. Refer to: Rear Seat Cushion .
- Remove the access cover and position aside.
- Disconnect electrical connector and fuel tube quick release coupling. Refer to: Quick Release Coupling
.
-
NOTE: Carefully install the Fuel Tank Sender Unit lock ring wrench to avoid damage to the Fuel Pump and Sender Unit when removing the lock ring.
Using the special tool remove the Fuel Pump and Sender Unit lock ring. Use Special Service Tool: 310-123 Locking Ring, Fuel Tank.
-
NOTE: The Fuel Pump and Sender Unit must be handled carefully to avoid damage to the float arm.
Position the Fuel Pump and Sender Unit aside. Using the Fuel Storage Tanker, completely drain the remaining fuel from the LH saddle of the fuel tank.
-
NOTE: Inspect the surfaces of the Fuel Pump and Sender Unit flange and 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 Pump and Sender Unit or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
- Remove the access cover and position aside.
-
NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the electrical connector and remove the quick release coupling. Refer to: Quick Release Coupling .
-
NOTE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the fuel level sensor when removing the lock ring.
Using the special tool remove the Fuel Level Sensor lock ring. Use Special Service Tool: 310-123 Locking Ring, Fuel Tank.
- Disconnect the internal fuel tube-to-Fuel Level Sensors quick connect couplings. Refer to: Quick Release Coupling
.
- Remove and discard the O-ring seal.