Fuel Level Sensor: Service and Repair

REMOVAL
1. Release the fuel pressure.
2. Disconnect negative battery cable.
3. Remove fuel tank.
4. Vacuum area before removing module lock ring.
5. Disconnect vapor line and electrical connector.

Locking Ring Contact Points:

6. Module lock ring contact points.

Module Locking Ring:

7. Remove module lock ring.

NOTE: Use a brass punch to remove the 1/4 turn lock ring.

8. Remove module top.
9. Tip module on to it's side to drain fuel from reservoir in module.
10. Drain fuel tank, use an approved gasoline draining station.
11. Disconnect electrical connector for fuel level sending card.

Sending Card Removal:

12. Remove fuel level sending card by prying on locking tab and pulling card down toward bottom of the pump module.

Sending Card Locking Tabs:

13 There are 2 locking tabs on sending card; one on the front and one on back.

INSTALLATION

Module Top Alignment Pins:

1. Install fuel level sending card to module.
2. Connect electrical connector for fuel level sending card.
3. Install module top to module.

Alignment Pins In Place:

4. Install module into the tank with the level unit towards rear of tank.
5. Install a new seal onto the tank, making sure seal is properly seated in tank groove.
6. Install module lock ring.

NOTE: Use a brass punch to Install the 1/4 turn lock ring. Make sure all 5 tabs are properly seated.

7. Connect vapor line and electrical connector.
8. Install fuel tank.
9. Connect negative battery cable.
10. Fill fuel tank. Use the scan tool to pressurize the fuel system. Check for leaks.