Secondary Fuel Level Sensor Replacement

Removal Procedure

Important: A NEW fuel tank module seal is necessary each time the fuel tank module is serviced. Obtain a NEW seal prior to beginning this service procedure.

Important: There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1 located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of the fuel pump modules.

1. Remove the fuel tank. Refer to Fuel Tank Replacement (AWD) (Service and Repair)Fuel Tank Replacement (FWD) (Service and Repair).
2. Remove the fuel pump module. Refer to Secondary Fuel Tank Module Replacement (Secondary Fuel Tank Module Replacement).
3. Disconnect the fuel level sender unit and the float electrical connector.
4. Release the retaining tabs and remove the level sensor by sliding up.

Installation Procedure

1. Install the fuel level sender unit and float onto the fuel pump module. Make sure that the sender cap snaps into place.
2. Connect the fuel level sender unit and the float electrical connector.
3. Install the fuel pump module into the fuel tank. Refer to Secondary Fuel Tank Module Replacement (Secondary Fuel Tank Module Replacement).
4. Install the fuel tank. Refer to Fuel Tank Replacement (AWD) (Service and Repair)Fuel Tank Replacement (FWD) (Service and Repair).

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

Secondary Fuel Level Sensor Replacement

Use the Manual With the Right Hardware

When to See a Mechanic

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