Fuel Gauge Sender: Service and Repair

FUEL LEVEL SENDING UNIT / SENSOR

REMOVAL
Remove fuel pump module. Service and Repair

Fig. 2 Fuel Pump/Level Sensor Electrical Connector:

1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of the fuel pump module electrical connector (Fig. 2)

NOTE: The pump module harness on TOP of flange is not serviceable or removable.

2. Pull off the locking wedge.

Fig. 3 Wire Terminal Locking Finger:

3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector (Fig. 3).

Fig. 4 Removing Wires From:

4. Push level sensor signal and ground terminals out of the connector (Fig. 4).

Fig. 5 Loosening Level Sensor:

5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing (Fig. 5). Push level sensor down slightly.

Fig. 6 Level Sensor Removal/Installation:

6. Slide level sensor wires through opening fuel pump module (Fig. 6).
7. Slide level sensor out of installation channel in module.

INSTALLATION
1. Insert level sensor wires into bottom of opening in module.

Fig. 7 Groove In Back Side Of Level Sensor:

2. Wrap wires into groove in back of level sensor (Fig. 7).

Fig. 8 Installation Channel:

3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place (Fig. 8) . Ensure tab at bottom of sensor locks in place.
4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position.
5. Install locking wedge on connector.
6. Push connector up into bottom of fuel pump module electrical connector.
7. Install fuel pump module.