For 1990-2009 cars

## Fuel Level Sensor Replacement RPO NT7

### Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

1. Remove the fuel pump module. Refer to Fuel Pump Module Replacement .
2. Push clockwise on the pressure sensor (1) in the 2 locations shown until an audible click is heard.
3. Raise the pressure sensor until the sensor is removed from the bucket.
4. Disconnect the fuel level sensor electrical connector (1) from the module cover.
5. Remove the fuel level sensor electrical connector wiring (2) from around the fuel pipe.
6. Push in the fuel level sensor retaining tabs (3) in order to disengage the sensor tabs from the module bucket.
7. Slide the fuel level sensor (1) up and out from the module bucket.

### Installation Procedure

1. Slide the fuel level sensor (1) in and down into the module bucket.
2. Ensure that the fuel level sensor retaining tabs (3) are fully engaged to the module bucket.
3. Wrap the fuel level sensor electrical connector wiring (2) around the fuel pipe.
4. Connect the fuel level sensor electrical connector (1) to the module cover.
5. Align the pressure sensor (1) to the hole in the bucket.
6. Push down and install the sensor to the bucket. Ensure that the sensor is secured to the bucket.
7. Install the fuel pump module. Refer to Fuel Pump Module Replacement .

## Fuel Level Sensor Replacement RPO NU6

#### Tools Required

J 45722 Fuel Sender Lock Ring Wrench

### Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Using the J 45722 , unlock the fuel sender lock ring.
3. Slowly lift the fuel pump flange up until the quick connect fittings (1) and fuel level sensor electrical connector are just visible.
4. Disconnect the fuel level sensor electrical connector from the fuel pump flange.
5. Disconnect the fuel tank vent valve and the fuel filter quick connect fittings (1) from the fuel pump flange. Refer to Plastic Collar Quick Connect Fitting Service .
6. Remove the fuel pump flange lock ring (1) and fuel pump flange (2). If required, remove the lock ring from the flange.
7. Remove and discard the fuel pump flange seal (3).
8. Squeeze the sides of the fuel level sensor retainer (2) together in order to remove the fuel level sensor.
9. Remove the fuel level sensor from the fuel pump module by sliding the sensor up.

### Installation Procedure

1. Position the fuel level sensor to the fuel pump module and slide the sensor down.
2. Ensure that the fuel level sensor retainer (2) is fully engages the fuel pump module.
3. Position a NEW fuel pump flange seal (3) onto the fuel tank.
4. If required, install the lock ring onto the flange. Position the fuel pump flange (2) and lock ring (1) over the fuel tank opening.
5. Ensure that the fuel pump flange tab is aligned with the arrow on the fuel tank.
6. Connect the fuel tank vent valve and the fuel filter quick connect fittings (1) to the fuel pump flange. Refer to Plastic Collar Quick Connect Fitting Service .
7. Connect the fuel level sensor electrical connector to the fuel pump flange.
8. Slowly lower the fuel pump flange into the fuel tank.
9. Using the J 45722 , lock the fuel sender lock ring.
10. Install the fuel tank. Refer to Fuel Tank Replacement .