Changing Ram Fuel Sensor: A Step-By-Step Guide

Changing a fuel pressure sensor in a RAM 1500 truck is a complex task that requires a range of tools and mechanical expertise. The process involves bleeding off the fuel pressure, disconnecting the battery, removing the snorkel and electrical connectors, loosening clamps, and carefully disconnecting the fuel line. It is important to take safety precautions, such as wearing safety glasses and using a rag to avoid fuel spillage. While some people opt to replace the entire fuel sending unit, others choose to replace just the sensor. The cost of replacement parts varies, with some opting for cheaper aftermarket alternatives.

Disconnect the battery and bleed off the fuel pressure

Disconnecting the battery and bleeding off the fuel pressure is an important step when changing the fuel sensor in a RAM truck. This process ensures that there is no pressure or power left in the fuel system, making it safe to work on. Here is a detailed guide on how to do this:

Firstly, locate the fuel pump fuse in the fuse box. Check the chart or manual to confirm that you have the right fuse. Pull out this fuse to disable the fuel pump. Now, start the vehicle and let it die. This will release any remaining pressure in the fuel system.

Once the vehicle has stalled, you can disconnect the battery. Use a suitable wrench, such as a 10-millimeter wrench, to loosen the battery terminal and slide it off. Set the battery aside in a safe place.

At this point, you can put the fuel pump fuse back into the fuse box. There should be no power to the fuse box now. You have successfully bled off the fuel pressure and can proceed with the next steps of changing the RAM fuel sensor. Remember to wear safety gear, such as safety glasses, and have a rag handy to catch any residual fuel.

It is important to follow these steps in the correct order to ensure your safety and avoid any potential issues when working on your RAM truck's fuel system.

Disconnect the electrical connector

To disconnect the electrical connector, you will need to first pull out the fuel pump fuse and confirm that you have the right fuse. Then, start the vehicle and let it die. Now, the fuel pressure is bled off, so you can disconnect the battery. Use a 10-millimetre wrench to disconnect the terminal and slide it off. Put the fuse back in so you don't forget. There is now no power to the fuse box.

Next, remove the snorkel and disconnect the connector. Push down on the tab and use a straight blade screwdriver to loosen the worm clamps. Slide off the snorkel and set it aside. Take off the cover by sliding it up and then forward. There are two pins that you can now slide out.

Finally, disconnect the electrical connector. You might need to use a pick to slide the little lock backwards, then push down on the tab and slide the connector up.

Disconnect the fuel line

Disconnecting the fuel line can be one of the more challenging tasks when changing a fuel sensor. There are various types of fuel line styles, each with its own method of disconnection.

For a push-type connector, you may need to push from both directions to release it, or simply push down and pull it off.

The push-and-lock style connector requires you to push it onto the fitting, then push the locking tab through. Beneath the fitting is a safety line. To remove this type, release the safety latch and push the connector back through.

The pinch-type connector has retainers on each side. To disconnect, pinch these together.

The spring-style retainer fitting has a black ring that serves as a release tool. Pull it back toward the fitting, then pull the fitting off.

The hose and clamp-style fitting is typically used for emissions lines. To remove it, use pliers to pinch the clamp together, slide it back, then pull the line off.

If you are having trouble disconnecting the fuel line, you may need a special tool. These can be purchased at auto parts stores. This tool goes around the fuel line and has an edge that is pressed into the fitting to relieve the pressure, allowing the connection to be pulled apart.

Remove the old sensor and slide the new one into the fuel line

To remove the old sensor, you will first need to bleed off the fuel pressure in the fuel system. Pull the fuel pump fuse and start the vehicle, letting it die. Now, disconnect the battery. Next, remove the snorkel and disconnect the connector, pushing down on the tab and using a straight blade screwdriver to loosen the worm clamps. Take off the cover by sliding it up and forward, and disconnect the electrical connector. You might need to use a pick to slide the lock backward before pushing down on the tab to slide the connector up.

Now, disconnect the fuel line. Use a pick to slide under the piece, pushing the lock down. Cover the opening with a rag to avoid getting fuel in your face, and wear safety glasses. Disconnect the line below, and slide the old sensor out.

To install the new sensor, simply reverse the process. Slide the new sensor into the fuel line, locking it in place. Slide the lock on first, then latch it. Push the other side of the line onto the fuel rail, locking the tab down. Reconnect the connector, lock it down, and push down the lock tab. Slide the cover back into position, and reconnect the snorkel, tightening the worm clamps. Reconnect the battery and cycle the key to let the fuel pressure prime. You can now start the truck.

Reconnect the electrical connector and battery

To reconnect the electrical connector and battery, follow these steps:

First, take the new fuel pressure sensor and slide it into the fuel line. Lock it in place. Take the lock and slide it onto the connector first, then latch it. Next, take the other side of the fuel line and slide it onto the fuel rail. Push the lock up and lock the tab down. Now, reconnect the electrical connector. Lock it down and push the lock tab down. Slide the cover back into position. Slide the pins in at the back first and push it down. Slide the snorkel back on, tighten the worm clamps, and reconnect the electrical connector. Finally, reconnect the battery and tighten the terminal.

Now, cycle the key on, let the fuel pressure prime, cycle it off, and cycle it on again. Then, start the truck.

It is important to note that safety precautions should be taken when working with fuel and electricity. Ensure that you are wearing appropriate safety gear, such as safety glasses, and that you are working in a well-ventilated area. It is also recommended to disconnect the battery before beginning any work on the vehicle's electrical system.

Frequently asked questions