Fuel Level Sensor: Service and Repair

FUEL LEVEL SENDING UNIT / SENSOR

REMOVAL
Remove fuel pump module.

Fig.1 Fuel Pump/Level Sensor Connector:

1. Depress the retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector.

Fig.2 Wire Terminal Retaining Clip:

Fig.3 Wire Terminal Identification:

2. Remove wire terminal retaining clip from connector. Note the location of terminals for the level sensor wires.

Fig.4 Level Sensor Signal:

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

Fig.5 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.6 Standpipe Inside Of Module:

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

INSTALLATION
1. Insert level sensor wires in bottom of standpipe.

Fig.7 Level Sensor:

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.