Fuel level sender

GENERAL INFORMATION

Warning: Refer to the precautions in Section 6.3.1 before starting work. Removal:

PROCEDURE

1. Disconnect the negative battery cable.

2. To gain access to the sender, remove the rear seat.

3. Remove the mounting screws and lift the cover to gain access to the sender.

4. Disconnect the sender electrical connector(s) and tape the connector to the vehicle body so that it does not fall into the fuel tank.

5. Relieve the fuel system pressure (see Section 6.3.1.7).

6. Mark the hoses so they are not mixed up, then loosen the hose clamps on the fuel supply hose and the return line hose.

7. Disconnect both hoses from the fuel level sender and plug the open hose ends.

8. Note the position of the alignment mark on the fuel level sender (the arrow must point toward the front of the vehicle). If there is no alignment mark, make one.

9. On models where the sender is secured by a large ring, unscrew and remove it from the fuel tank. This is best done using a screwdriver inserted into the notch on the edge of the locking ring. Carefully tapping the screwdriver, turn the locking ring counterclockwise until it can be turned by hand.

10. On models where the sender is secured by bolts, remove all mounting bolts and washers.

11. On all models, carefully lift the sender out of the top of the fuel tank, taking care not to bend the float arm and not to spill fuel onto the seat or interior trim.

12. When removing the sender, disconnect the fuel pump electrical connector. Reach into the fuel tank and squeeze the retaining clip to remove the fuel pump from the bottom of the fuel tank.

13. The fuel pump and fuel level sender can then be removed together from the fuel tank.

14. Remove the rubber sealing ring and discard it. A new ring must be used during installation.

15. Loosen the retaining clamp, then disconnect the fuel pump hose from the bottom of the fuel level sender, and remove the sender from the pump.

16. Wash the fuel filter in a high flash point solvent.

17. Inspect the filter for signs of clogging or cracks and replace it if necessary.

Installation

PROCEDURE

1. Installation is the reverse of the removal procedure.

2. When installing, pay attention to the following points.

3. Install the fuel level sender on the fuel pump, making sure the hoses are correctly connected and securely fastened with clamps.

4. Install a new rubber sealing ring on the fuel tank.

5. Make sure the fuel pump is securely fastened before installing the fuel level sender.

6. If the sender is secured by a locking ring, align the mark on the sender with the mark on the fuel tank, and tighten the ring securely.

7. If the sender is secured by bolts, align the marks on the sender and the fuel tank made before removal, and tighten all mounting bolts securely.

8. Check that the fuel supply and return lines are correctly connected and tighten the hose clamps securely.

9. Before installing the cover, connect the battery, then start the engine and check the fuel hoses for signs of fuel leakage.