Fuel Level Sensor: Service and Repair

FUEL LEVEL SENSOR







Exploded View

Removal

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are present and may be ignited. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

1. Remove the fuel pump module.







2. NOTE: Note the routing of the sending unit wire for installation.

Unwrap the sending unit wire from the rest of the fuel pump module wire harness.







3. Remove the heat shrink tube covering the electrical connector.







4. Disconnect the electrical connector.







5. Remove the screw and lift up to remove the fuel gauge sending unit.

Installation







1. Route the fuel gauge sending unit wire through the center of the fuel pump module.







2. NOTE: Both fuel gauge sending unit wires must be routed behind the metal sending unit plate.

Hook the fuel gauge sending unit on the fuel pump module.







3. NOTE: The grounding eyelet must be on the front side of the sending unit.

Install the screw through the grounding eyelet and tighten the screw.







4. Slide the heat shrink tube onto the wire harness and connect the electrical connector.







5. WARNING: Do not use an open flame to heat the heat shrink tube, only use a heat gun.

Using a heat gun, heat the heat shrink tube.







6. Wrap the sending unit wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm.
7. Install the fuel pump module.