Fuel Level Sensor Replacement (Long Wheelbase)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5599040 Single Use Fasteners and Components Fuel Sender Seal Special Tools CH–45722 Fuel Sender Lock Ring Wrench Equivalent regional tools: Special Tools

Warning

Refer to Diesel/Gasoline Vapors Warning.

Warning

Refer to Safety Glasses Warning. Removal Procedure

1. Relieve the fuel system pressure. Fuel Pressure Relief
2. Drain the fuel tank. Fuel Tank Draining
3. Raise and support the vehicle. Lifting and Jacking the Vehicle

Fuel Level Sensor Replacement (Long Wheelbase) — figure 1

4. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Remove [4x]
5. Remove both rear stabilizer shaft clamp (2) from the frame and let the stabilizer shaft hang.

Fuel Level Sensor Replacement (Long Wheelbase) — figure 2

6. Evaporative Emission Canister Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
7. Evaporative Emission Canister Filter Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
8. Fuel Feed Hose (3) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Level Sensor Replacement (Long Wheelbase) — figure 3

9. Evaporative Emission Canister Solenoid (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
10. Fuel Tank Filler Hose Clamp (2) » Loosen
11. Fuel Tank Filler Hose (3) » Remove
12. Fuel Tank Filler Vent Hose (4) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Level Sensor Replacement (Long Wheelbase) — figure 4

13. Place a suitable adjustable jack under the fuel tank.
14. Strap fuel tank to jack.
15. Fuel Tank Strap Bolt (1) » Remove [2x]
16. Fuel Tank Strap (2) » Remove [2x]

Fuel Level Sensor Replacement (Long Wheelbase) — figure 5

17. Lower the fuel tank, allowing clearance to access connections at the top of the tank.
18. Electrical Connector (1) » Disconnect [3x]
19. Fuel Feed Hose Clip (2) » Disengage
20. Wiring Harness Retainer (3) » Disengage [2x]
21. Retainer (4) » Unclip

Fuel Level Sensor Replacement (Long Wheelbase) — figure 6

22. Fuel Tank (1) » Remove

Fuel Level Sensor Replacement (Long Wheelbase) — figure 7

Fuel Level Sensor Replacement (Long Wheelbase) — figure 8

24. Fuel Tank Filler Vent Hose (1) @ Fuel Tank Fuel Pump Module » Disconnect — Plastic Collar Quick Connect Fitting Service
25. Fuel Tank Filler Vent Hose (1) » Reposition

Fuel Level Sensor Replacement (Long Wheelbase) — figure 9

26. Evaporative Emission Canister Vent Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
27. Evaporative Emission Canister Vent Hose (2) » Reposition

Fuel Level Sensor Replacement (Long Wheelbase) — figure 10

28. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Disengage [2x]
29. Fuel Feed Hose (2) @ Fuel Tank Fuel Pump Module » Disconnect — Plastic Collar Quick Connect Fitting Service
30. Fuel Feed Hose (2) » Reposition

Fuel Level Sensor Replacement (Long Wheelbase) — figure 11

31. Fuel Sender Retainer (1) » Remove — CH–45722 Fuel Sender Lock Ring Wrench(2)

Fuel Level Sensor Replacement (Long Wheelbase) — figure 12

32. Fuel Tank Vent Valve Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Level Sensor Replacement (Long Wheelbase) — figure 13

33. Fuel Tank Fuel Pump Module (1) » Remove
34. Fuel Sender Seal (2) » Remove and DISCARD

Fuel Level Sensor Replacement (Long Wheelbase) — figure 14

35. Disconnect the fuel level sensor electrical connector.

36. Fuel Level Sensor (1) » Remove Installation Procedure

37. Fuel Level Sensor (1) » Install

38. Connect the fuel level sensor electrical connector.

39. Fuel Tank Vent Valve Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

40. Fuel Sender Seal (2) » Install NEW

41. Fuel Tank Fuel Pump Module (1) » Install

42. Fuel Sender Retainer (1) » Install — CH–45722 Fuel Sender Lock Ring Wrench(2)

43. Fuel Feed Hose (2) » Install

44. Fuel Feed Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

45. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Engage [2x]

46. Evaporative Emission Canister Vent Hose (2) » Install

47. Evaporative Emission Canister Vent Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

48. Fuel Tank Filler Vent Hose (1) » Install

49. Fuel Tank Filler Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

50. Tape (1) » Install

51. Place a suitable adjustable jack under the fuel tank.

52. Strap fuel tank to jack.

53. Raise the fuel tank  (1), allowing access to connections at the top of the tank.

54. Retainer (4) » Clip

55. Wiring Harness Retainer (3) » Engage [2x]

56. Fuel Feed Hose Clip (2) » Engage

57. Electrical Connector (1) » Connect [3x]

58. Raise the tank to the installed position.

59. Fuel Tank Strap (2) » Install [2x]

Caution

Refer to Fastener Caution.

24. Fuel Tank Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications

25. Fuel Tank Filler Vent Hose (4) » Connect — Plastic Collar Quick Connect Fitting Service

26. Fuel Tank Filler Hose (3) » Install

27. Fuel Tank Filler Hose Clamp (2) » Tighten — Fastener Specifications

28. Evaporative Emission Canister Solenoid (1) » Connect — Plastic Collar Quick Connect Fitting Service

29. Fuel Feed Hose (3) » Connect — Plastic Collar Quick Connect Fitting Service

30. Evaporative Emission Canister Filter Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

31. Evaporative Emission Canister Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

32. Raise rear stabilizer shaft into installed position.

33. Rear Stabilizer Shaft Clamp (2) » Install [2x]

34. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Install and tighten [4x] — Fastener Specifications

35. Lower the vehicle.

36. Refill the fuel tank.

37. Inspect for fuel leaks.