Fuel Level Sensor Location:
The fuel level sensor assembly on the 1991 Jeep YJ Wrangler is located inside the fuel tank.
Do You Have to Drop the Tank to Get to It?
Yes. To access and replace the fuel level sensor assembly, you must drop the fuel tank.
Replacement Instructions:
Important Note: Before starting any work, make sure the vehicle is turned off and the parking brake is engaged. Additionally, it's recommended to have at least a quarter tank of fuel in the vehicle.
Tools Required:
- Flat-head screwdriver
- Phillips-head screwdriver
- Box wrench set
- Pliers
- Flashlight
Procedure:
1. Prepare the Vehicle:
- Park the vehicle on a level surface.
- Turn off the vehicle and engage the parking brake.
- Open the fuel door and remove the gas cap.
2. Locate Fuel Tank:
- Locate the fuel tank under the rear of the vehicle.
3. Disconnect Fuel Lines:
- Disconnect the fuel lines going to the fuel tank. Be sure to place a rag underneath to catch any spilled fuel.
4. Remove Fuel Tank Straps:
- Locate and remove the fuel tank straps holding the fuel tank in place.
5. Lower Fuel Tank:
- Use a floor jack or ramps to raise the rear of the vehicle.
- Carefully lower the fuel tank by using a rope or chain tied around the tank.
- Make sure not to apply downward force on the fuel lines or electrical connections.
6. Remove Sensor Assembly:
- Once the tank is lowered enough to be accessible, locate the fuel level sensor assembly.
- Remove the electrical connector and disconnect the fuel line from the assembly.
- Use the appropriate wrench to remove the retaining nut.
7. Install New Sensor Assembly:
- Place the new fuel level sensor assembly in the tank.
- Hand-tighten the retaining nut.
- Reconnect the fuel line and electrical connector.
8. Secure Tank and Reconnect Lines:
- Carefully raise the fuel tank back into position and reconnect the fuel lines and straps.
- Lower the vehicle back down.
- Reconnect the negative battery terminal (if disconnected).
Testing:
Add some fuel to the tank and turn on the ignition to verify the fuel gauge functioning correctly.
Note:
If the fuel gauge is not working after the replacement, check the electrical connection or replace the fuel gauge itself.
