GM 19418353
Fuel Gauge Sending Unit

First step for replacing the Fuel Level Sensor in a malibu sedan requires separating the Fuel Pump module assembly. Disconnect the Fuel Level Sensor electric connector from the pump module cover after releasing the wiring harness from its molded-in tab on the pump module bowl. Push the retaining tab of the sensor then pull the level sensor backward from the pump module while taking care to fully extract it. Insert the new Fuel Level Sensor into the slots present on the Fuel Pump module bowl before setting the retaining tab within its mounting slot. You should attach the Fuel Level Sensor electrical connector to the pump module cover and afterward place the wiring harness onto the molded-in tab on the pump module bowl before reinstalling the Fuel Pump module assembly.

The j 45722 Fuel Level Sensor lock ring wrench alone should be used for disconnecting evap and fuel feed lines from the Fuel Level Sensor assembly to prevent damage to the lock ring. Secure the Fuel Tank to prevent rotation because only significant force will release the lock ring while handling of the Fuel Level Sensor assembly by fuel pipes must be avoided to maintain joint integrity. Apply the j 45722 to the Fuel Level Sensor lock ring followed by a long breaker-bar while rotating counterclockwise to unlock it then remove the Fuel Level Sensor assembly together with the seal and discard the seal. Wash the Fuel Level Sensor sealing areas while checking the lock ring for damage; change the lock ring if it shows warping greater than 0.41 mm (0.016 in). A new seal must be used for the Fuel Level Sensor assembly installation while the Fuel Pump Strainer remains horizontal and the float arm stays obstruction-free. Fit the Fuel Level Sensor assembly with the lock ring while utilizing the j 45722 tool to guide correct installation of clockwise rotation. The final step involves attaching the fuel feed along with evap lines to the sensor assembly then reinstalling the Fuel Tank.

Depress the retaining tab on the sensor and slide the level sensor away from the pump module, then carefully remove it completely.

Inspect for fuel leaks by cycling the ignition and checking for any signs of leakage.