OEM 2002 Dodge Ram 2500 Van Fuel Level Sensor

2002 Dodge Ram 2500 Van Fuel Level Sensor Parts and Q&A

• Q: How to remove and install the Fuel Level Sensor on 2002 Dodge Ram 2500 Van?

  A: It is required by law that the fuel gauge pressure sensor or sending unit, be connected to a fuel control valve set at the back of the left-mounted fuel cylinder in front of the left-rear spring perch. It is necessary to purge the fuel system of compressed natural gas before removing the sensor. First, it's important to purge the CNG system. Lift the Allen head set screw on the side of the red manual fuel shut-off valve handle and lift the handle out. Then, unscrew the bolts that hold the fuel cylinder shield, with twelve Torx headed and two hex headed bolts. Wipe the space around the sensor by the fuel control valve, remove the electrical connector at the sensor, then use a wrench at the sensor base to unbolt it, not the sensor case. Initially, apply Parker O-Lube onto the O-ring on the sensor and mount the unit to the fuel control valve; tighten it to a torque of 27 Nm (20 ft.lbs.) Fasten the electrical connector to the sensor and run a CNG leak test. Fix the cylinder shield in place and tighten all the bolts. The two nuts need 11 Nm (100 in. lbs.) and the twelve Torx headed bolts require 28 Nm (250 in. lbs.). Smear Mopar Neverseize Compound onto the area near the end of the manual shut-off valve where it touches the red handle, unscrew the Allen head set screw from the side of the shut-off valve handle, maneuver the handle to reach the extension shaft, persue the set screw with blue Loctite 242 and tighten it.