Fuel Gauge Sender: Service and Repair

Fig. 14 Fuel Pump/Level Sensor Electrical Connector:

[1][2]FUEL LEVEL SENSOR
The fuel level sensor attaches to the side of the fuel pump module. Remove the fuel pump module to replace the fuel level sensor. Refer to Fuel Pump Module Removal .

Fig. 14 Fuel Pump/Level Sensor Electrical Connector:

NOTE: Remove fuel pump module to gain access to this sensor.

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

Fig. 15 Terminal Removal Tool:

2. Using Special Tool #C-4334 terminal remover or equivalent, remove terminals from level sensor connector.

Fig. 16 Loosening Level Sensor:

3. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly.
4. Slide level sensor wires through opening fuel pump module.
5. Slide level sensor out of installation channel in module.

Fig. 17 Groove In Back Side Of Level Sensor:

INSTALLATION
1. Insert level sensor wires into bottom of opening in module.
2. Wrap wires into groove in back of level sensor.

Fig. 18 Installation Channel:

3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place. Ensure tab at bottom of sensor locks in place.

Fig. 19 Fuel Pump/Level Sensor Electrical Connector:

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.