OEM 2003 Dodge Ram 3500 Van Fuel Level Sensor

2003 Dodge Ram 3500 Van Fuel Level Sensor Parts and Q&A

• Q: How is the Fuel Level Sensor installed and removed on 2003 Dodge Ram 3500 Van?

  A: The fuel level sensor is placed to a fuel control valve that sits at the rear end of the left-side mounted fuel cylinder in front of the left-rear spring perch. Before taking out the sensor, remove all compressed natural gas from the fuel system. The first step is to evacuate everything from the CNG fuel system. The new step is to loosen the Allen screw set on the side of the red handle and then remove the entire handle. When you are done draining the fuel, remove the fuel cylinder shield by taking out twelve Torx headed bolts and two hex headed bolts. Remove any dirt around the sensor at the fuel control valve, pull out the electrical connector from the sensor and use a wrench at the sensor's bottom to withdraw it, preventing you from holding on to the case. Put Parker O-Lube on the O-ring of the sensor, put the sensor onto the fuel control valve and ensure it is secure at 27 Nm (20 ft. lbs.) torque. Connect the electrical connector to the sensor again and run a CNG leak test. Fit the cylinder shield, then install all 14 bolts, tightening the smaller two bolts to 11 Nm and the Torx headed bolts to 28 Nm. Use some Mopar Neverseize Compound on the end of the manual shut-off valve that touches the red handle. Remove the Allen head set screw from the handle and its side, fit the handle onto the extension shaft, put blue Loctite 242 onto the set screw and screw it back in.