This procedure covers the removal and replacement of the fuel level sensor by accessing the fuel pump assembly through the rear seat area of the vehicle.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — Use OEM specification
• Fuel pump assembly O-ring × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure fuel tank is less than half full to minimize spillage (drain if necessary)
3. Open driver's door and leave open throughout procedure to prevent accidental locking
4. Disconnect negative battery terminal and wait 90 seconds minimum
5. Remove rear seat cushion by pulling up firmly on front edge to release clips
6. Gather all tools and new parts including O-rings before beginning

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump relay in the engine compartment fuse box (marked EFI or FUEL PUMP, typically in position 20-30 depending on model year). Remove the relay. Reconnect battery temporarily, start the engine and let it run until it stalls from fuel starvation. Attempt to start the engine 2-3 more times to ensure pressure is fully relieved. Disconnect battery negative terminal again.
   ⚠️Even after relieving pressure, residual fuel remains in lines. Have towels ready when disconnecting fittings.
2. 2

   Remove fuel pump access cover
   Locate the rectangular fuel pump access cover in the floor under the rear seat. Remove the sound insulation material if present. Remove the screws securing the metal or plastic access cover (typically 4 screws). Carefully lift and remove the cover to expose the fuel pump assembly.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)
3. 3

   Disconnect electrical connector
   Locate the electrical connector on top of the fuel pump assembly. Press the release tab and carefully disconnect the connector. Ensure the connector is positioned away from the work area to prevent contamination.
4. 4

   Disconnect fuel lines
   Identify the fuel feed and return lines connected to the pump assembly. Place shop towels around the connections to catch fuel. Using the appropriate size fuel line disconnect tool, press the tool onto the quick-connect fitting and pull the line away from the pump. Repeat for the second line. Plug the lines with clean rags or caps to prevent contamination.
   ⚠Fuel will drain from lines. Have drain pan positioned to catch spillage.
5. 5

   Remove fuel pump lock ring
   The fuel pump assembly is secured by a large circular lock ring with notches or tabs. Using a brass drift and plastic mallet (or specialized lock ring tool if available), tap the ring counterclockwise to loosen. Once loose, carefully unthread the ring by hand and remove it completely. Keep the ring clean and free of debris.
   ⚠Do not use steel tools that could create sparks. Use brass or plastic tools only.
6. 6

   Extract fuel pump assembly
   Carefully lift the fuel pump assembly straight up out of the fuel tank. Tilt it slightly to navigate the float arm and fuel level sensor through the opening. Fuel will drain from the assembly - hold it over the tank opening until draining stops, then place in a fuel-safe drain pan. Note the orientation of the assembly for reinstallation.
   ⚠Float arm and fuel level sensor are fragile. Avoid bending or damaging these components during removal.
7. 7

   Remove old fuel level sensor
   With the pump assembly removed, locate the fuel level sensor attached to the side of the assembly. The sensor consists of a float arm connected to a variable resistor. Disconnect the internal electrical connector from the sensor to the pump module. Remove the retaining clip or screws securing the sensor to the pump housing (typically 1-2 small screws or a spring clip). Carefully slide the sensor and float arm assembly out of its mounting position.
8. 8

   Install new fuel level sensor
   Position the new fuel level sensor into the mounting location on the pump assembly, ensuring the float arm moves freely through its full range of motion without binding. Secure with the retaining clip or screws. Connect the internal electrical connector, ensuring it clicks into place. Verify the float arm is not bent and moves smoothly from empty to full position.
   ℹ️Compare old and new sensors to verify correct replacement part before installation.
9. 9

   Inspect and replace O-ring
   Remove the old O-ring from the groove on top of the fuel tank opening. Clean the groove thoroughly with a lint-free cloth, removing any debris or old gasket material. Install the new O-ring into the groove, ensuring it seats evenly all the way around without twisting or pinching.
   ⚠Do not lubricate O-ring with petroleum-based products. If lubrication is needed, use only fresh gasoline.
10. 10

    Reinstall fuel pump assembly
    Carefully lower the fuel pump assembly back into the tank opening, guiding the float arm and sensor through first. Align the assembly with any locating tabs or marks noted during removal. Press down gently to seat the assembly against the O-ring. Ensure the assembly sits flush and level.
11. 11

    Install lock ring
    Thread the lock ring onto the fuel pump assembly by hand, turning clockwise. Once hand-tight, use the brass drift and plastic mallet to tap the ring clockwise until fully tightened. The ring should be secure but do not over-tighten as this can damage the plastic tank threads.
12. 12

    Reconnect fuel lines
    Install new O-rings on the fuel line fittings. Push each fuel line firmly onto its respective connection on the pump assembly until you hear and feel a click. Tug on each line to verify it is locked in place and will not pull free.
    ℹ️Lines must click into place. If they do not, inspect the connector for damage and verify correct orientation.
13. 13

    Reconnect electrical connector and test
    Connect the electrical connector to the fuel pump assembly, ensuring it clicks securely. Reconnect the battery negative terminal. Turn the ignition to ON position (do not start) and listen for the fuel pump to prime (2-3 seconds of running). Turn ignition off, then on again 2-3 times to build fuel pressure. Inspect all connections for leaks.
    ⚠️If any fuel leakage is detected, immediately disconnect battery and repair leak before proceeding.
14. 14

    Reinstall access cover
    Once no leaks are confirmed, reinstall the fuel pump access cover and secure with screws to specified torque. Reinstall sound insulation if equipped. Reinstall rear seat cushion by aligning clips and pressing firmly until all clips engage.
    Torque spec

    Cover Screws10 Nm (8 lb-ft)

Reassembly

1. Reinstall fuel pump relay in engine compartment fuse box
2. Double-check all electrical connections are secure
3. Verify rear seat is properly installed and all clips engaged
4. Clean any fuel residue from interior surfaces with appropriate cleaner

Verification

• Start the engine and verify it runs smoothly without stumbling or fuel pressure issues
• Allow engine to idle for 2-3 minutes while monitoring for fuel odors or leaks under rear seat
• Check fuel gauge operation - it should read current fuel level accurately (may take 10-20 seconds to stabilize after key-on)
• Test drive vehicle and monitor fuel gauge through a range of fuel levels if possible
• Verify no warning lights (check engine, low fuel) are illuminated on instrument cluster
• Recheck all connections under access cover after test drive for any signs of leakage

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