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Fuel Level Sensor

Powertrain Management › Sensors and Switches - Powertrain Management
Unified entry — merged from multiple cross-listed pages in the original manual.
Procedures
Fuel Level Sending Unit And Sensor - Removal3 steps
Fig. 1
Fig. 1
  1. Drain and remove fuel tank (4).
  2. Remove the fuel pump module Fuel Tank - Removal
  3. Remove the fuel level sending unit.
Fuel Level Sending Unit And Sensor - Installation3 steps
Fig. 1
Fig. 1
  1. Install the fuel level sending unit to the module.
  2. Install the fuel pump module in the tank Fuel Tank - Installation.
  3. Install fuel tank (4) Fuel Tank - Installation.
Fuel Pump Module - Removal9 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
⚠ WARNING
The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.
ℹ NOTE
Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
ℹ NOTE
The fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
⚠ WARNING
The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.
ℹ NOTE
Do not spill fuel into the interior of the vehicle.
Fig. 1
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Fig. 6
Fig. 6
  1. Drain and remove fuel tank Fuel Tank - Removal.
  2. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  4. Rotate the breaker bar counterclockwise and remove the lock-ring.
  5. Mark the fuel pump module orientation.
  6. Raise the fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle.
  7. Tip the fuel pump module on its side and drain all fuel from the reservoir.
  8. Remove the fuel pump module from the fuel tank using caution not to bend the float arm.
  9. Remove and discard the rubber O-ring seal.
Fuel Pump Module - Installation8 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
△ CAUTION
Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.
ℹ NOTE
The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
  1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal.
  2. Lower the fuel pump module into the fuel tank using caution not to bend the float arm.
  3. Align the rubber O-ring seal and rotate the fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.
  4. Position the lock-ring over top of the fuel pump module.
  5. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  6. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  7. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged.
  8. Install the fuel tank Fuel Tank - Installation.
Fuel Level Sending Unit And Sensor - Removal3 steps
Fig. 1
Fig. 1
  1. Drain and remove fuel tank (4).
  2. Remove the fuel pump module Fuel Tank - Removal
  3. Remove the fuel level sending unit.
Fuel Level Sending Unit And Sensor - Installation3 steps
Fig. 1
Fig. 1
  1. Install the fuel level sending unit to the module.
  2. Install the fuel pump module in the tank Fuel Tank - Installation.
  3. Install fuel tank (4) Fuel Tank - Installation.
Fuel Pump Module - Removal9 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
⚠ WARNING
The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.
ℹ NOTE
Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
ℹ NOTE
The fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
⚠ WARNING
The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.
ℹ NOTE
Do not spill fuel into the interior of the vehicle.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
Fig. 6
Fig. 6
  1. Drain and remove fuel tank Fuel Tank - Removal.
  2. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  4. Rotate the breaker bar counterclockwise and remove the lock-ring.
  5. Mark the fuel pump module orientation.
  6. Raise the fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle.
  7. Tip the fuel pump module on its side and drain all fuel from the reservoir.
  8. Remove the fuel pump module from the fuel tank using caution not to bend the float arm.
  9. Remove and discard the rubber O-ring seal.
Fuel Pump Module - Installation8 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
△ CAUTION
Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.
ℹ NOTE
The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
  1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal.
  2. Lower the fuel pump module into the fuel tank using caution not to bend the float arm.
  3. Align the rubber O-ring seal and rotate the fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.
  4. Position the lock-ring over top of the fuel pump module.
  5. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  6. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  7. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged.
  8. Install the fuel tank Fuel Tank - Installation.
Fuel Level Sending Unit And Sensor - Removal3 steps
Fig. 1
Fig. 1
  1. Drain and remove fuel tank (4).
  2. Remove the fuel pump module Fuel Tank - Removal
  3. Remove the fuel level sending unit.
Fuel Level Sending Unit And Sensor - Installation3 steps
Fig. 1
Fig. 1
  1. Install the fuel level sending unit to the module.
  2. Install the fuel pump module in the tank Fuel Tank - Installation.
  3. Install fuel tank (4) Fuel Tank - Installation.
Fuel Pump Module - Removal9 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
⚠ WARNING
The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.
ℹ NOTE
Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
ℹ NOTE
The fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
⚠ WARNING
The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.
ℹ NOTE
Do not spill fuel into the interior of the vehicle.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
Fig. 6
Fig. 6
  1. Drain and remove fuel tank Fuel Tank - Removal.
  2. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  4. Rotate the breaker bar counterclockwise and remove the lock-ring.
  5. Mark the fuel pump module orientation.
  6. Raise the fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle.
  7. Tip the fuel pump module on its side and drain all fuel from the reservoir.
  8. Remove the fuel pump module from the fuel tank using caution not to bend the float arm.
  9. Remove and discard the rubber O-ring seal.
Fuel Pump Module - Installation8 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
△ CAUTION
Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.
ℹ NOTE
The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
  1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal.
  2. Lower the fuel pump module into the fuel tank using caution not to bend the float arm.
  3. Align the rubber O-ring seal and rotate the fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.
  4. Position the lock-ring over top of the fuel pump module.
  5. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  6. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  7. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged.
  8. Install the fuel tank Fuel Tank - Installation.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
FUEL LEVEL SENDING UNIT SENSOR📷 1
The fuel gauge sending unit (fuel level sensor) is attached to the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card).
The sensor is serviceable.
figure
SENSOR-FUEL LEVEL SENDING UNIT📷 1
1. Drain and remove fuel tank (4). (Refer to REMOVAL ). 2. Remove the fuel pump module. See REMOVAL. 3. Remove the fuel level sending unit.
figure
SENSOR-FUEL LEVEL SENDING UNIT📷 1
1. Install the fuel level sending unit to the module. 2. Install the fuel pump module in the tank. See INSTALLATION.
3. Install fuel tank (4). See INSTALLATION.
LINES-FUEL
figure