Fuel Level Sender

FUEL LEVEL SENDER

Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Remove the fuel pump module.







2. NOTE: Note the routing of the fuel level sender wire for installation.

Unwrap the fuel level sender wire from the rest of the fuel pump module wire harness.







3. Remove the heat shrink tube covering the electrical connector.







4. Disconnect the electrical connector.







5. NOTE: Gasoline shown, flexible fuel similar.

Remove the screw and lift up to remove the fuel level sender.

Installation

All vehicles







1. Route the fuel level sender wire through the center of the fuel pump module.

Gasoline vehicles







2. NOTE:
- Both fuel level sender wires must be routed behind the metal fuel level sender plate.
- The grounding eyelet must be on the front side of the fuel level sender.

Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw.

Flexible fuel vehicles







3. NOTE:
- One fuel level sender wire routes behind the fuel level sender and one routes along the left side of the fuel level sender.
- The grounding eyelet must be on the front side of the fuel level sender.

Hook the fuel level sender on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. Clip the wire into the clip on the fuel pump module.

All vehicles







4. Slide the heat shrink tube onto the wire harness and connect the electrical connector.







5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury.

Using a heat gun, heat the heat shrink tube.







6. Wrap the fuel level sender wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm.
7. Install the fuel pump module.