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TheEngineer -> Fuel Level Sensor (4/24/2008 6:57:05 AM)
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Courtesy of Mankoosho:
Today I attempted to take it out the Fuel level sensor. In my car, and in most cars, it is located on the rear car seat. Keep in mind though, that there are some cars that do not allow you access to this sensor from the top....In that case, you have to take down the fuel tank.
The fuel sensor I am talking about is the conventional needle type one. Most modern cars these days have an LCD display of the amount of fuel in tank.
You should turn the car on, and then pull out the plug located on the car fuel level sensor. For some cars, there is a fuse or a relay for the fuel, in that case, you would turn that car on and then unplug the fuse or relay. The car would stay on for a couple of seconds, and then the motor would slowly turn off. Through this attempt, you are releasing the fuel pressure in the fuel pipes. (Shown in pictures below)
[image]http://img410.imageshack.us/img410/4267/img0231tw9.jpg[/image]
The fuel level sensor is located under this black metal cover
[image]http://img294.imageshack.us/img294/8861/img0233cx8.jpg[/image]
The fuel level sensor, located under the cover
[image]http://img294.imageshack.us/img294/3808/img0234zy4.jpg[/image]
Close up of the fuel level sensor, showing all the wires and pipes
On top of this sensor, there are two small rubber pipes attached. One is for fuel coming in, and one for fuel coming out of the tank.
In the picture above, you can see a black frame surrounding the fuel level sensor. This frame is the one that is firmly holding down the sensor. You need to unscrew it, by simply turning it anti-clockwise, in order to take out the sensor.
Today's fuel contains many sulfur contents that may cause the sensor to give inaccurate readings. In order to clean the part of the sensor that gives the reading (Note: known as fuel level sending unit), you need to spray that part of the sensor with some sort of cleaner (e.g: WD-40). To get best results, you could use a small tooth brush to rub the solvent and remove any rust.
You may not find this problem in your car, but there is a wire connected from the part of the sensor that gives the reading (mentioned above), to the to top of the sensor. This sends the reading through the plug that we removed earlier, to the gas gauge located in your dashboard. This wire was worn out, so I personally cut this wire out (which is possibly 4 cm long), and molded a new wire in place.
After you finish all of the mentioned above, you need to return the sensor to its place. You simply place the sensor back in the tank the same way you got it out, and then screw back the black plastic frame. Return the plug and put the pipes back in their place.
This should do the job! Its not a tough one, but you are dealing with a very sensitive part of the car, so be careful.
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