Replace the fuel level sensor in the fuel tank assembly, requiring fuel tank removal and careful handling of fuel system components.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — Use OEM specification
• Fuel pump module O-ring seal × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification
• Tank strap mounting hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and isolate from battery post
3. Drain or siphon fuel tank to below 1/4 capacity to reduce weight and spillage risk
4. Raise and safely support vehicle on jack stands rated for vehicle weight
5. Remove spare tire if mounted under vehicle to access fuel tank
6. Place approved fuel storage containers and absorbent material under work area

Procedure

1. 1

   Relieve fuel system pressure
   Although diesel systems operate at lower pressure than gasoline, residual pressure exists. Remove the fuel pump relay from the power distribution center (under hood) if applicable, or proceed carefully with fuel line disconnection. Have shop towels ready to catch any fuel spillage.
2. 2

   Disconnect fuel tank filler neck
   Loosen the hose clamp securing the filler neck hose to the fuel tank using appropriate tool. Carefully separate the filler neck from the tank. Diesel fuel will drain from this connection, so have a drain pan positioned underneath.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect fuel lines at tank
   Using fuel line disconnect tools, disconnect the fuel supply and return lines from the fuel tank module. These are quick-connect fittings. Press the release tabs while pulling the lines straight off. Cap or plug open lines to prevent contamination. Inspect O-rings and discard old ones.
   ⚠Some fuel will spill from lines and tank connections. Have absorbent material ready and work carefully to minimize spillage.
4. 4

   Disconnect electrical connector
   Locate the fuel pump module electrical connector on top of the fuel tank. Press the release tab and disconnect the connector. Ensure connector is positioned away from tank removal path.
5. 5

   Disconnect vent lines
   Disconnect the EVAP vent lines and any other vapor lines connected to the fuel tank. Note routing and connection points for reinstallation.
6. 6

   Support and remove fuel tank
   Position a transmission jack or use ratchet straps to support the fuel tank weight. Remove the tank strap mounting bolts on both sides of the tank. Carefully lower the tank while ensuring all connections are clear. Guide tank down and out from under vehicle with assistance.
   ⚠️Even partially filled, the fuel tank is extremely heavy. Use proper support and get assistance to prevent crushing injuries.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
7. 7

   Remove fuel pump module lock ring
   Clean the top of the fuel tank around the fuel pump module to prevent contamination. Using the lock ring spanner tool, rotate the lock ring counterclockwise to unlock. A plastic dead blow hammer may be used to tap the spanner tool. Remove the lock ring completely.
8. 8

   Remove fuel pump module
   Carefully lift the fuel pump module straight up and out of the tank. Tip the module to one side to allow the fuel level sensor float arm to clear the tank opening without damage. Drain residual fuel from the module into an approved container. Place module on clean work surface.
   ⚠The fuel level sensor float arm extends from the module and is easily damaged. Handle with care during removal.
9. 9

   Remove and replace fuel level sensor
   Disconnect the fuel level sensor electrical connector from the fuel pump module. Release the locking tabs or remove fasteners securing the fuel level sensor to the module assembly. Remove the old sensor and float arm assembly. Install the new fuel level sensor, ensuring all electrical connections are secure and locking tabs engage properly. Verify float arm moves freely through its full range of motion.
10. 10

    Install fuel pump module
    Inspect and replace the large O-ring seal on the fuel tank opening. Ensure tank opening is clean and free of debris. Carefully lower the fuel pump module into the tank, guiding the fuel level sensor float arm to prevent damage. Align the module orientation marks with tank marks. Press module down until seated.
11. 11

    Install lock ring
    Install the lock ring and rotate clockwise using the spanner tool until fully seated and locked. Verify the module is secure and properly sealed.
12. 12

    Reinstall fuel tank
    With assistance, lift the fuel tank back into position under the vehicle using the transmission jack or support straps. Align mounting points and install tank strap mounting bolts. Torque bolts to specification in a cross pattern to ensure even support.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
13. 13

    Reconnect all connections
    Install new O-rings on fuel line fittings lubricated with clean diesel fuel. Reconnect fuel supply and return lines to tank module, ensuring they click into place. Reconnect electrical connector to fuel pump module. Reconnect all EVAP and vent lines. Reconnect filler neck hose to tank and install hose clamp, torquing to specification.
    ℹ️Always use new O-rings on fuel line connections. Reusing old O-rings can cause fuel leaks.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
14. 14

    Reinstall spare tire and lower vehicle
    If spare tire was removed, reinstall it in the proper mounting location. Remove jack stands and carefully lower vehicle to ground. Reconnect negative battery cable.
15. 15

    Refuel and test system
    Add fuel to tank if it was drained. Turn ignition to ON position without starting engine to prime fuel system. Cycle ignition 3-4 times. Inspect all fuel connections for leaks. Start engine and verify it runs properly. Check fuel gauge operation through full range by monitoring as fuel is added.
    ⚠Carefully inspect all fuel connections for leaks before and after starting engine. Address any leaks immediately.

Reassembly

1. Torque all fasteners to specification using values provided
2. Use new O-rings on all fuel line connections
3. Verify all electrical connectors are fully seated and locked
4. Ensure fuel tank straps are properly positioned and torqued evenly
5. Route all fuel and vent lines in original positions without kinks or interference

Verification

• Turn ignition to ON position and verify fuel pump operates (listen for fuel pump hum)
• Check fuel gauge reads accurately at current fuel level
• Inspect all fuel line connections, tank seams, and filler neck for leaks with engine running
• Test drive vehicle and monitor fuel gauge operation - it should respond to fuel consumption
• Verify no fuel odor in cabin or under vehicle after test drive
• Clear any diagnostic trouble codes related to fuel level sensor if present

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