Fuel Level Sensor

This procedure covers the removal and replacement of the fuel level sensor located in the fuel tank on a 2017 Maserati Levante with 3.0L V6 Twin Turbo engine.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — Use OEM specification
• Fuel pump module O-ring × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Ensure fuel tank is less than 1/4 full. If necessary, siphon or drain excess fuel into approved containers
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery cable and wait 10 minutes for system capacitors to discharge
4. Remove rear seat cushion by pulling upward firmly at front edge to release clips
5. Remove rear seat back by releasing lower mounting bolts and lifting upward

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump fuse in the rear fuse box (Fuse F48). Remove the fuse and attempt to start the engine. Allow the engine to run until it stalls from fuel starvation. Attempt to start the engine 2-3 more times to ensure all residual pressure is released. Turn ignition to OFF position.
   ⚠Engine will run rough and stall quickly. This is normal during fuel pressure relief procedure.
2. 2

   Access fuel pump module cover
   Remove the sound deadening material from the floor pan beneath the rear seat. Locate the plastic access cover for the fuel pump module in the center of the floor pan. Remove the cover screws and carefully lift the cover away to expose the fuel pump module assembly.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect electrical connector
   Press the release tab on the fuel pump module electrical connector and carefully pull the connector straight up to disconnect. Ensure the connector is positioned away from the work area to prevent fuel contamination.
4. 4

   Disconnect fuel supply and return lines
   Using the appropriate fuel line disconnect tools, compress the quick-connect fittings and pull the fuel supply and return lines straight off the pump module. Be prepared for residual fuel spillage. Place shop towels around the connections and have a catch pan ready. Inspect the line fittings for damage.
   ⚠Residual fuel will drain from lines. Keep shop towels and catch pan ready to contain spills.
5. 5

   Remove fuel pump lock ring
   Using the fuel pump lock ring tool, rotate the lock ring counterclockwise to unlock. The ring may require significant force to break free initially. Once loosened, remove the lock ring completely and set aside.
6. 6

   Remove fuel pump module
   Carefully lift the fuel pump module assembly upward and out of the fuel tank. Tilt the module to angle the fuel level sensor float arm through the tank opening. Allow residual fuel to drain back into the tank. Place the module on shop towels in a clean work area.
   ⚠Module contains residual fuel and delicate components. Handle carefully to avoid damage to fuel level sensor float arm.
7. 7

   Remove old fuel level sensor
   Locate the fuel level sensor on the side of the pump module assembly. Disconnect the internal electrical connector from the sensor. Remove the sensor mounting bracket screws and carefully slide the sensor and float arm assembly out of the module housing. Inspect the float arm for damage or fuel saturation.
   Torque spec

   Bracket Bolts21 Nm (16 lb-ft)
8. 8

   Install new fuel level sensor
   Position the new fuel level sensor into the module housing, ensuring the float arm moves freely through its full range of motion. Install the sensor mounting bracket and secure with bracket bolts torqued to specification. Connect the internal electrical connector to the sensor until it clicks into place.
   Torque spec

   Bracket Bolts21 Nm (16 lb-ft)
9. 9

   Inspect and replace O-ring
   Remove the old O-ring from the top of the fuel pump module. Clean the O-ring groove thoroughly with a lint-free cloth. Lubricate the new O-ring lightly with clean engine oil and install it into the groove, ensuring it seats properly without twists or folds.
10. 10

    Reinstall fuel pump module
    Carefully lower the fuel pump module assembly into the fuel tank, tilting as necessary to guide the float arm through the opening. Align the module so that the alignment marks on the module and tank flange match. Press the module down firmly until it seats against the O-ring.
11. 11

    Install and secure lock ring
    Position the lock ring over the fuel pump module and engage the threads. Using the lock ring tool, rotate the lock ring clockwise until it is fully seated and tight. Verify the lock ring is secure and the module cannot rotate.
12. 12

    Reconnect fuel lines
    Install new O-rings on both fuel supply and return line fittings. Lubricate the O-rings lightly with clean engine oil. Push each fuel line firmly onto the module connections until the quick-connect fitting clicks into place. Verify security by gently pulling on each line.
    ℹ️Always use new O-rings on fuel line connections to prevent leaks.
13. 13

    Reconnect electrical connector
    Align the fuel pump module electrical connector and push it firmly onto the module until it clicks into place. Verify the locking tab is fully engaged.
14. 14

    Reinstall access cover
    Position the access cover over the fuel pump module opening. Install and torque the cover screws to specification. Reinstall the sound deadening material to the floor pan.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Reinstall rear seat back by aligning mounting points and securing lower bolts
2. Reinstall rear seat cushion by aligning clips and pressing firmly until all clips engage
3. Reinstall fuel pump fuse F48 in rear fuse box
4. Reconnect negative battery cable and tighten securely

Verification

• Turn ignition to ON position (do not start engine) and listen for fuel pump priming for 2-3 seconds. Repeat this cycle 3-4 times to pressurize the fuel system
• Inspect all fuel line connections at the pump module for leaks while system is pressurized
• Start the engine and verify it runs smoothly without fuel starvation symptoms
• Using a diagnostic scan tool, verify the fuel level sensor reading matches the actual fuel level in the tank
• Check for diagnostic trouble codes related to fuel system or fuel level sensor
• Test fuel gauge operation by observing gauge response matches fuel level
• Verify no fuel odor is present in cabin or from rear seat area

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