Fuel Level Sensor Replacement Procedure

Removal





1. The Fuel Pump Module has a single (in-tank) sub-harness that must be disconnected from the Fuel Pump Module Mounting Flange Connector.

2. Using a small pair of needle-nosed pliers, remove and retain the secondary terminal lock from the sub-harness electrical connector.





3. Using a suitable terminal release tool (similar to Snap-on # YA500GM), depress the lock tang for terminals 1 and 6, then pull the terminals out through the back of the connector.

Note:
The Fuel Level Sensor Terminals have a beveled edge which requires proper orientation when reinstalling in the connector. Carefully note their location by wire color in the connector prior to removal.





4. Using a suitable pair of diagonal cutters, cut off the two (2) Fuel Level Sensor Terminals previously released/removed from the sub-harness connector, then discard those terminals.





5. Disengage the Fuel Level Sensor wires from the retaining hook at the top of the Fuel Pump Module Body, then pull the cut wire ends out of the fuel pump body through the built-in tube.





6. Pull the Low Fuel Level Sensor from its bracket.

7. Using a small flat-blade screwdriver, release the Low Fuel Level Sensor Bracket from the Fuel Pump Module Body by prying it in the direction shown. The bracket will slide through the retaining rail as you pull it free of the Fuel Pump Module Body.

Note:
Prying in the opposite direction may cause damage to the lock that retains the Low Fuel Sensor Bracket.





8. Remove the Fuel Level Sensor by prying it in the same direction from the same retaining rail that previously held the Low Fuel Sensor Bracket.

Installation

9. Temporarily wrap the new Fuel Level Sensor wire terminals with electrical tape.





10. Route the wire through the groove at the bottom of the Fuel Level Sensor as you route it around to the back of the Fuel Level Sensor Body.

Note:
Failure to propertly mute the Wire in the remote may cause the wire to be damaged as the Fuel Level Sensor is installed.





11. Guide the Fuel Level Sensor Body onto the retaining rail on the Fuel Pump Module Body. Slide it fully into place on the retaining rail. An audible "click" will be heard as it locks into it's proper position.

Note:
Failure to properly lock the Fuel Level Sensor into place will affect its accuracy.

12. Route the Fuel Level Sensor wires through the built-in tube in the Fuel Pump Module Body.





13. Route the Fuel Level Sensor wires through the retaining hook on top of the Fuel Pump Module Body.

14. Remove the electrical tape, then insert the Fuel Level Sensor Terminals into the Fuel Pump Module Sub-harness Electrical Connector. Ensure that the terminals are properly reinstalled (as noted previously) and that the correct wire colors are in their proper connector location. Also, verify that the terminals are locked into position by gently tugging on the wires after installation.

Note:
The forward-most edge of the beveled terminal face should be oriented towards the "outboard" edges of the terminal housing.





15. Once the terminals are properly positioned, reinstall the secondary terminal lock into the connector. Reconnect the sub-harness connector to the Fuel Pump Module Mounting Flange Connector.





16. Guide the Low Fuel Level Sensor Bracket onto the retaining rail on the Fuel Pump Module Body. An audible "click" will be heard as it locks into it's proper position.

17. Reinsert the Low Fuel Level Sensor onto its bracket.

18. Test the new Fuel Level Sensor by using the procedure described in steps 18 through 23 of the Fuel Level Sensor Diagnostic Procedure before reinstalling the Fuel Pump Module into the Fuel Tank.

19. Using a new 0-ring, carefully reinstall the Fuel Pump Module into the Fuel Tank. Take care not to damage the O-ring or bend the Fuel Level Sensor Float Arm.

CAUTION:
Removing components from a sealed fuel system exposes fuel vapors to outside oxygen and possible sources of combustion. A fuel system should only be opened in a properly ventilated area. Special caution should be used when removing components from a fuel tank or fuel system. Removal of such components should only be done away from open flame (torches, lit cigarettes, heater pilots or other flames however minor) or sparks (mechanical, electrical or otherwise) that could cause fuel vapors to ignite.

20. Using a suitable hammer and brass drift, reinstall the Fuel Pump Module Retaining Ring by rotating it clockwise until it reaches it's stops.

21. Reconnect the wiring Harness Connector to the Mounting Flange Connector on the Fuel Pump Module.

22. Reinstall the Fuel Pump Outlet Hose by pushing it firmly into place. An audible "click" will be heard when the hose is properly connected.

23. Reinstall the Fuel Tank Return Hose by pushing it firmly into place. An audible "click" will be heard when the hose is properly connected.

24. Reinstall the Fuel Pump Relay into the Engine Compartment Fuel/Relay Box.

25. Turn the Ignition Switch to the "ON" position and verify that the Fuel Pump operates for approximately 3 seconds by listening for pump motor operation, then check the Fuel Pump Module for leaks.

26. Road test the vehicle, then recheck the area around the Fuel Pump Module for fuel leaks.

27. Reinstall the Fuel Pump Module Access Cover by pressing it into place.

28. Reinstall the rear seat cushion.

Lanos ONLY - Reinstall the Rear Seat Cushion retaining bolt removed previously.