GM 19210797
Fuel Gauge Sending Unit

The first step for Fuel Level Sensor replacement requires removal of the Fuel Tank. The first step is to disconnect both electrical connectors from the fuel sender module then handle the Fuel Level Sensor with care to prevent damaging the fuel pipe joints. You should remove fuel pipes from the fuel sender by using only the fuel sender lock ring wrench (J 45722) to protect the lock ring from damage. First use the j 45722 along with a specific long breaker-bar tool set to reverse-turn the fuel sender lock ring in a counterclockwise direction. Separate the Fuel Level Sensor and lock ring from the Fuel Tank by removing them one after another and discard the damaged fuel sender seal. Check the lock ring for any damage as well as warping and perform a ring replacement if needed. The next step involves installing the Fuel Level Sensor to the fuel sender module before cleaning the fuel sender sealing flange for new fuel sender seal installation within the Fuel Tank seal groove. Place the fuel sender lock ring and Fuel Level Sensor inside the Fuel Tank with the proper orientation so it will rotate in a clockwise direction. The technician should use j 45722 to install the fuel sender lock ring before reattaching both fuel pipes and the Fuel Level Sensor electrical connectors and finally reinstalling the Fuel Tank.

The first step for replacing the Fuel Level Sensor (RPO NU6) is to uninstall the Fuel Tank. Lawfully access the Fuel Level Sensor lock ring by first detaching both the evap lines and fuel line from the sensor while relocating the evap and fuel feed components. The j 45722 Fuel Level Sensor lock ring wrench must be used to turn counterclockwise on the lock ring after which care must be taken to avoid damaging either component or touching the Fuel Level Sensor by the fuel pipes. The o-ring seal from the Fuel Level Sensor requires discarding during the process. Clean the sealing surfaces before continuing. One should replace the lock ring when flatness measures higher than 0.41 mm (0.016 in) because of damage or warping. Position a new Fuel Level Sensor o-ring seal onto the Fuel Tank followed by installing the Fuel Level Sensor with correct placement of its alignment tab before putting in the Fuel Tank lock ring. Fitting a new Fuel Level Sensor seal while following up with proper lock ring installation that requires clockwise rotation when completing the process. The j 45722 tool should be used to install the lock ring before you reconnect the fuel line and evap lines to the sensor. Finally, reinstall the Fuel Tank.

Connect the fuel level sensor electrical connector.

Use a small bladed tool to push in the electrical terminals while pulling them out.

Use a small bladed tool to push in the electrical terminals while pulling them out.

Discard the O-ring seal and clean the sealing surfaces.