Changing the Gas Tank Level Sender

Jim had a problem where the gas gauge would read full, then empty, then settle down, but at a point higher than it should have been.  He traced it down to a faulty fuel level sensor.  Jim changed it out and sent in photos.

WARNING!  This article involves the fuel system of your car.  Gasoline is HIGHLY flammable and one small spark can turn your car (and yourself) into a huge fireball!  If you have a problem with your gas gauge or the fuel system, take the car to a mechanic.

To emphasize the danger, here are the warnings from the service manual:

Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk.  To recude the rick of fire and increased exposure to vapors:

• Use forced air ventilation such as a fan set outside of the trunk.
• Plug or cap any fuel system openings in order to reduce fuel vapor formation.
• Clean up any spilled fuel immediately.
• Avoide sparks and any source of ignition.
• Use signs to alert others in the work area that fuel system work is in process.

Don't forget to disconnect the negative terminal of the battery!

Also, make sure you clean all hose connections and areas around these connections to avoid possible contamination of the system.

The following is an abridged version of the instructions:

	The fuel sender can be accessed from inside of the vehicle.  This way you do not have to drop the tank.  Remove the spare tire cover, jack and spare tire.  Pull back the carpet.
	Remove the nuts from the fuel sender access panel.  Disconnect the fuel tank pressure sensor and fuel sender electrical connectors.  Clean the fuel pipes and sender assembly to prevent fuel contamination.  Prior to disconnecting the fuel pipes, remove the gas cap to relieve pressure in the tank.  Then connect the Fuel Pressure Gauge Fitting (J 34730-262) to the fuel pressure connection.  Connect Fuel Pressure Gauge (J 34730-1A) to that.  Wrap a shop towel around the connection to avoid spillage.  Install the bleed hose and open the valve to bleed the system into an approved container.  Disconnect the quick-connect fittings.
	Remove the fuel sender retaining ring.  The assembly will spring up when the ring is removed.  Remove the modular fuel sender assembly.  Clean all seating surfaces.
	This is the modular fuel sender assembly.
	Fuel level sender switch.
	New fuel sender switch assembly (left) and old (right)
	Re-assemble and reinstall.  Connect the electrical connectors.  Put a few drops of clean engine oil on the male end of the quick-disconnect fittings before connecting them.  Reconnect the battery cable.  Turn the ignition ON for two seconds, turn OFF for 10 seconds, turn ON and check for fuel leaks.  Turn the igntion OFF and replace the access panel.

Again, if you have a problem with your fuel system, do not attempt the repair yourself.  Have a professional mechanic fix it.  Thanks to Jim for the photos!