GM 88965379
Fuel Gauge Sending Unit

The fuel level sensor replacement process begins by taking out the sending unit and unconnecting the fuel pump electrical connector. Proceed by taking away the retaining clip from the fuel lever sensor electrical connector before unplugging the fuel level sensor electrical connector. You need to eliminate the fuel level sensor by first unfastening its retaining clip. The installation process begins with attaching the fuel level sensor before fastening it with the retaining clip. You should connect the fuel level sensor electrical connector followed by installing its retaining clip. Reconnect the fuel pump electrical connector and reinstall the sending unit as the last step.

The necessary tool for Fuel Level Sensor assembly replacement is the Fuel Level Sensor lock ring wrench (J 45722). You must start your work with Fuel Tank removal and disconnect the fuel line and the evaporative emission (EVAP) line from the sensor unit. The Fuel Level Sensor lock ring wrench (J 45722) should be combined with a long breaker-bar for unlocking the Fuel Level Sensor lock ring while draining fuel from the assembly into an approved container for safety purposes. Use only the Fuel Level Sensor lock ring wrench (J 45722) to uninstall the lock ring without touching fuel pipes on the sensor assembly. This will stop joint damage from occurring. Using tools with impact becomes necessary only when releasing the lock ring requires strong force and operating with hammers and screwdrivers must be avoided. Secure the Fuel Tank at all times to stop its movement. Discard the removed sensor unit seal before you start cleaning both sealing surfaces. Use seven points of measurement with the feeler gauge to check the lock ring's flat surface clearance. A lock ring requires replacement if its warpage measurement exceeds 0.41 mm (0.016 in) but can be utilized when it remains undamaged during inspection. Before final installation the system requires a new sensor unit seal and correct placement of the fuel strainer at a horizontal angle not to block the float arm. The Fuel Level Sensor lock ring wrench (J 45722) should be used to tighten the lock ring clockwise when installing the sensor unit. Reinstalling the Fuel Level Sensor seal must be done with a new one and verify the lock ring position is proper. Last in the Fuel Tank reinstallation sequence is the attachment of the evap line and fuel line to the sensor unit.

The fuel level sensor replacement process begins by taking out the sending unit and unconnecting the fuel pump electrical connector. Proceed by taking away the retaining clip from the fuel lever sensor electrical connector before unplugging the fuel level sensor electrical connector. You need to eliminate the fuel level sensor by first unfastening its retaining clip. The installation process begins with attaching the fuel level sensor before fastening it with the retaining clip. You should connect the fuel level sensor electrical connector followed by installing its retaining clip. Reconnect the fuel pump electrical connector and reinstall the sending unit as the last step.

Substituting the Fuel Level Sensor in the 35 reg/ext/crew cab with its 34-gallon tank requires removing the fuel tank module first. Detach the wiring pigtail of the Fuel Level Sensor electrical connector from its position on the module cover before extracting the wiring pigtail from beneath the clip of the module. The Fuel Level Sensor retainers need gentle pressure to exit the module reservoir before pulling the sensor out of its slot. Position the Fuel Level Sensor over the slot in the reservoir before you slide it down into the slot until the retainers engage the module reservoir. The wiring pigtail should be installed beneath the module clip after fuel pump wires then connect its electrical connector to the module cover prior to reinstalling the fuel tank module.

Use only the Fuel Sender Lock Ring Wrench (J 45722).

Start by installing the fuel level sensor and its retaining clip.

Always replace the fuel sender gasket to reduce fire risk and ensure the fuel strainer is horizontal to avoid blocking the float arm.

Connect the fuel level sensor electrical connector and install the retaining clip for the fuel level sensor electrical connector.

Remove the fuel level sensor retaining clip and then take out the fuel level sensor.

To minimize the risk of fuel leaks.