Fuel Gauge Sender: Service and Repair

Fig 14 Fuel Pump/Level Sensor Connector:

REMOVAL
Remove fuel pump module. Refer to Fuel Pump Module.
1. Depress the retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector.

Fig 15 Wire Terminal Retaining Clip:

2. Remove wire terminal retaining clip from connector.

Fig 16 Wire Terminal Identification:

- Note the location of terminals for the level sensor wires.

Fig 17 Level Sensor Signal And Ground Wires:

3. Using special tool 7812 or an equivalent, push level sensor signal and ground terminals out of the connector.

Fig 18 Fuel Level Sensor Removal:

4. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly.

Fig 19 Standpipe Inside Module:

5. Slide level sensor wires through standpipe inside fuel pump module.
6. Slide level sensor out of installation channel.

Fig 20 Level Sensor Installation:

INSTALLATION
1. Insert level sensor wires in bottom of stand- pipe.
2. Wrap wires into groove in back of level sensor.
3. While feeding wires into standpipe, slide level sensor up into installation channel until it snaps into place.
- 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 retaining clip on connector.
6. Push fuel pump/level sensor connector up into bottom of fuel pump module electrical connector.
7. Install fuel pump module. Refer to Fuel Pump Module.