Fuel Level Sensor: Service and Repair

Sender Unit and Float

TOOLS REQUIRED
^ SA9156E Fuel Tank Lock Ring Remover

REMOVAL

CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE.

1. Remove fuel tank.




2. Remove fuel lines and electrical connectors from fuel pump cover.

NOTE: To prevent retaining ring damage, DO NOT attempt to remove retaining ring with a 12 in. or shorter ratchet/breaker bar. Operation should be a smooth one hand operation while holding onto the lock ring.




3. Use the Fuel Tank Lock Ring Remover SA9156E and remove fuel pump module retaining ring. A 1/2 in. breaker bar (approximately 18 inches long) will easily loosen and remove the lock ring.

NOTE: To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 45°.

4. Remove fuel pump from fuel tank.

IMPORTANT: The fuel pump assembly is only serviced as a module without the sender unit. The inlet filter can be cleaned with mineral spirits; however, it cannot be replaced.




5. Remove wires from clip.




6. Remove positive and negative connectors from top of pump.




7. Remove connector housing from bottom side of fuel pump cover. (Disengage locking tab with fingernail or small flat black screwdriver.)




8. Remove fuel level sender card by depressing locking tab and sliding the card up (toward fuel pump cover).

INSTALLATION
1. Slide new sender unit into place until click is heard. (Pulling up lightly to ensure sender unit is locked into place.)

IMPORTANT: Verify that float arm on sender unit maintains correct relationship to pump module by standing module on a flat, horizontal surface. The float should lay on the surface.




2. Connect electrical connections.

IMPORTANT: The fuel pump module to tank seal must always be replaced whenever module is removed from fuel tank.

3. Install pump module and lock ring using a new tank seal.
4. Reconnect fuel lines & electrical connectors to fuel pump.
5. Install fuel tank.