GM 19121938
Fuel Gauge Sending Unit

You can start the nu6 Fuel Level Sensor replacement by releasing fuel system pressure together with removing the rear compartment liner from the vehicle. The first step involves removing the bolts and then the cover of the Fuel Level Sensor access hole. Disconnect the fuel feed rear pipe quick connect fitting along with the evaporative emission (EVAP) pipe quick connect fitting and the Fuel Level Sensor wiring harness electrical connectors from the sensor. Move the fuel feed pipe along with evap pipe and harness connector to an alternative position. The Fuel Level Sensor lock ring wrench (J 45722) should be used to unlock the Fuel Level Sensor lock ring but users need to protect the ring from damage during manipulation. Position the sensor slightly upward while removing its vent line quick connect fitting. When the vapor line quick connect fittings (1 and 2) become visible one should slowly raise the module while securing the internal vent lines with a string to stop them from entering into gasoline. Lower the sensor retrogradely from the fuel tank opening to discard the content into an approved receptacle. Replace the fuel pump sensor o-ring seal and inspect the lock ring for damage which should be replaced if it is warped more than 0.41 mm (0.016 in). To perform the installation first place a new fuel pump sensor o-ring seal onto the fuel tank followed by lowering the sensor into the tank while keeping the float arm clear. Connect quick connect components 1 and 2 in the internal vent line before cutting the securing string to install the sensor locking component. Secure the lock ring in a clockwise direction with the Fuel Level Sensor lock ring wrench (J 45722). Reconnect the vent quick connect fitting from the fuel tank followed by the fuel feed rear pipe quick connect fitting and Fuel Level Sensor wiring harness electrical connector. The last step is to connect the negative Battery Cable while inspecting for leaks through ignition cycling followed by installation of the Fuel Level Sensor access hole cover and bolts to reinstall the rear compartment liner.

Connect the fuel level sensor electrical connector under the module cover, pushing it up until the clip engages.

Gently lift up on the locking tab and continue sliding the sensor up until it engages the tab.

Avoid handling the fuel sender assembly by the fuel pipes to prevent damage.

Gently lift the locking tab and continue sliding the sensor up until it engages the tab.

Make sure the level sensor wires are not pinched between the module and sensor.