Replacing Fuel Level Sensor: Step-By-Step Guide For Diyers

A fuel level sensor, or gasoline gauge, is a device that shows the amount of fuel remaining in a vehicle's tank. While it is widely used in automobiles, it can also be useful for any reservoir, such as underground storage tanks. If your fuel sensor is not working, your gas gauge will not read correctly, and your car may not pass inspection. You can either take your car to a professional, who will charge around $450 to install a new fuel sensor, or you can attempt to replace the fuel sensor yourself for under $100.

Disconnect the negative battery cable

Disconnecting the negative battery cable is one of the first steps to take when replacing a fuel level sensor. Here is a detailed, step-by-step guide on how to do this:

Step 1: Park Your Vehicle

Park your vehicle on a flat, hard surface and ensure that the transmission is in park for automatics or in first gear for manual vehicles. This step is important for your safety and to ensure that your vehicle does not move during the repair process.

Step 2: Engage Parking Brake and Place Wheel Chocks

Engage the parking brake to lock the rear tires from moving. Additionally, place wheel chocks around the front tires to provide extra security and prevent the vehicle from rolling.

Step 3: Open the Vehicle's Hood

Before disconnecting the battery cable, you will need to access the engine compartment by opening the vehicle's hood. This will allow you to locate the battery and its negative cable.

Step 4: Locate the Battery and Negative Cable

Once the hood is open, locate the battery. The negative cable is connected to the battery's negative post, which is usually marked with a "-" sign or black color. The cable may also be black to indicate its polarity.

Step 5: Disconnect the Negative Battery Cable

Using the appropriate tools, carefully loosen and remove the negative battery cable from the battery post. This step is crucial as it disables the power to the fuel pump and sending unit, ensuring that you can work safely on the fuel system. Place the cable in a safe location, ensuring it does not touch any metal parts of the vehicle to prevent short circuits.

At this point, you have successfully disconnected the negative battery cable. Remember to follow safety protocols and refer to a trusted repair guide or mechanic for further instructions on replacing the fuel level sensor.

Remove the spare tire

To remove the spare tire, first open the trunk and take out the spare tire. If your vehicle has a chain and winch system, use the jack handle to spin the chain winch to lower the tire. Once the spare tire is on the ground, tilt the bracket and slide it through the hole in the wheel. If your vehicle has a bolt with three holes, lower the tire first and then unscrew the bolt. You can also refer to your owner's manual for detailed instructions on removing the spare tire.

• Locate the jack handle and the winch: The jack handle is usually stored in the trunk or cargo area, and the winch is typically located near the trailer hitch.
• Assemble the jack handle: If the jack handle has multiple extensions, put them together.
• Engage the winch: Insert the pointed or looped end of the jack handle into the winch. Make sure it is securely engaged.
• Lower the spare tire: Turn the jack handle in the counter-clockwise direction to lower the tire. Continue turning until the tire reaches the ground with some slack in the chain.
• Tilt the bracket: Once the tire is on the ground, tilt the bracket that holds the tire and slide it through the hole in the wheel. This will release the tire from the chain.
• Store the spare tire: After removing the tire from the chain, you can store it in your desired location.

It is important to note that the process of removing the spare tire may vary slightly depending on the make and model of your vehicle. Always refer to your owner's manual or seek assistance from a qualified mechanic if you are unsure about any steps.

Detach gas and electric power cables

To replace the fuel level sensor, you will need to first detach the gas and electric power cables. Here is a detailed, step-by-step guide on how to do this:

Locate the negative battery cable and disconnect it. This is an important safety precaution as it will prevent any accidental electrical shorts or sparks during the replacement process.

Next, you will need to access the fuel tank. Depending on your vehicle, this may involve raising the rear hatch, opening the trunk, or removing the back seat bottom. If your vehicle has a spare tire, you may need to remove it to access the fuel tank.

Once you have accessed the fuel tank, locate the gas and electric power cables connected to it. These cables provide power to the fuel sensor and allow it to communicate with the vehicle's systems. Using appropriate tools, carefully detach these cables from the fuel tank. Label each cable or take note of their connections to ensure proper reassembly.

After detaching the cables, it is important to secure the fuel tank in place to avoid any accidental spills or damage. You may need to use a jack or a support mechanism to hold the tank in place while you work.

At this point, you have successfully detached the gas and electric power cables from the fuel tank. You can now proceed to the next step, which is detaching the fuel tank itself. Remember to work carefully and refer to your vehicle's repair manual or seek professional guidance if needed.

Safety should always be a top priority when working on your vehicle, especially when dealing with flammable liquids and electrical systems. Ensure you are wearing appropriate protective gear, including gloves and eye protection, and have adequate ventilation during the replacement process.

Unclip electrical cables and remove tank holders

To unclip the electrical cables and remove the tank holders, you will need a pair of small screwdrivers. Use the screwdrivers to unclip the electrical cables. Then, take out the three bolts on the bearers that support the tank under the vehicle.

Gradually move the vehicle's gas tank down. It is easier to handle the tank with less gasoline in it, so consider draining the tank before you begin. You can ask a friend to help you hold the tank, with each person on either end.

Once the tank is lowered, you can remove the tank holders.

Remove the transmitting device

To remove the transmitting device, you will need to first remove the clips on the electrical attachment at the top of the device. It is important to note that you should not detach the gas pipe during this step, as fuel will come out of the tank.

Next, use a screwdriver and a hammer to rotate the lock ring at the top of the transmitting device. Line up the lock tabs and channels by rotating the lock ring. To minimise friction when removing the lock ring, spray it with lubricating oil. Once the lock ring is off, you can take out the transmitting device from the gas tank.

The fuel level sensor is typically located at the bottom of the transmitting device. To remove the sensor, simply remove the clip from the harness and slide it off.

If there is insufficient space to access the transmitting unit, you will need to reduce the volume of fuel in the tank. Lower the fuel volume to around a quarter of a tank of gasoline to create more space.

Frequently asked questions