Fuel Level Sensor: Service and Repair

Fuel Sender Assembly Replacement

Removal Procedure




Caution: Refer to Relieving Fuel Pressure Caution (Technician Safety Information).
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Fuel Pressure Relief).
2. Remove the fuel pump assembly. Refer to Fuel Pump Replacement (Service and Repair).




3. Disconnect the insulator connector





Important: The wedge may be disconnected with severe force but can be reconnected.


4. Push the terminal wedge (1) in the insulator connector




5. Remove the fuel level sensor (1) from the sender housing (2).
6. Remove the sender housing.




7. Remove the fuel sender assembly (3).

Installation Procedure




1. Install the wires (1) into the sender assembly (2).





Important: Ensure the sender assembly and the fuel level sensor are installed properly. If not the fuel gauge and fuel level warning indicator will not function properly.


2. Install the sender assembly onto the fuel pump assembly (1).
3. Install the fuel level sensor onto the sender housing.
4. Connect the wire into the insulator connector.




5. Connect the insulator connector
6. Install the fuel pump assembly into the fuel tank. Refer to Fuel Pump Replacement (Service and Repair).