GM 25322887
Fuel Gauge Sending Unit

Safety begins when you acquire a dry chemical (Class B) fire extinguisher and establish exhaust ventilation and the replacement of the Fuel Level Sensor. Women jobbers should always use protective goggles and they must clean all fuel pipe connections alongside their surrounding environment to avoid pollution. The first step should be to reduce fuel system pressure while draining all fuel from the tank until it reaches a 3/4 full level. Disassemble the rear spare tire elements starting with the cover and jack followed by removing the floor trim which will protect against static discharges. Begin by taking out both the compartment trim panel replacement - rear along with the needed Fuel Level Sensor access panel. You should disconnect both the quick-connect fittings along with the electrical connectors that service the Fuel Level Sensor and the Fuel Tank pressure sensor. To remove the modular Fuel Level Sensor you should tip it while being careful to avoid float damage and transfer residual fuel to an authorized container. The maintenance professional should employ the j 39675 Fuel Level Sensor spanner wrench to detach both the Fuel Level Sensor retaining ring and retainer cam before extracting the Fuel Level Sensor while discarding the o-ring. Surface inspection of Fuel Tank o-ring seals should happen before applying a new rubber o-ring seal onto the Fuel Tank. The installation process requires proper Fuel Level Sensor placement with retainer cam alongside a proper orientation of the Fuel Pump Strainer to avoid twisting or folding. The j 39765 Fuel Level Sensor spanner wrench should be used to install the Fuel Level Sensor and retainer cam followed by reconnection of the quick-connect fittings and electrical connectors. Let the negative Battery Cable reestablish its connection before you confirm leak-free operation when you activate the ignition switch off and on. Complete the procedure by securing the Fuel Level Sensor access panel with 2 nm of torque (18 lb in) then put back the rear compartment trim panel along with the spare tire, jack, and spare tire cover while filling the tank with fuel and closing the Fuel Tank filler cap.

A proper Fuel Level Sensor service requires users first to release fuel system pressure before draining the Fuel Tank reservoir. Test the position of the fuel strainer by inspecting its installation. Handle the reservoir with one hand while gripping the fuel strainer with your other hand until you place the upside-down Fuel Level Sensor assembly on a workbench to uninstall the fuel sender strainer. The fuel sender strainer requires an inspection if contaminated which leads to Fuel Tank cleaning and disposal of the Fuel Level Sensor after checking it. Proceed by disconnecting both electrical connectors from the Fuel Pump assembly and the Fuel Level Sensor unit. Afterwards disconnect the Fuel Level Sensor assembly. A new fuel level strainer must always be installed before mounting either fuel sender or Fuel Level Sensor assemblies onto their fuel sender and verifying complete proper seating. Attach the Fuel Level Sensor assembly after installing it and join its electrical connectors to the Fuel Pump and cover assembly. Use proper fasteners in designated positions while installation while also selecting parts with correct numbers for proper usage but never apply paints or lubricants or corrosion inhibitors to fasteners. After installing the Fuel Level Sensor assembly, users should pour fuel into the tank before attaching the Fuel Tank filler cap before they can reconnect the negative Battery Cable. The inspection for fuel leaks requires a two-second ignition switch turn on followed by a ten-second switch off before continuing to examine for leaks.

Almost every replacement process depends on two essential tools - fuel pressure gauge (J 34730-1A) and Fuel Level Sensor lock nut wrench (J 39765). The first step requires both fuel system pressure relief and enough fuel tank draining to reach 3/4 of the tank to avoid fuel leakage. First remove the spare tire cover and jack and spare tire before extracting the rear compartment floor trim to gain safe access to the metal components. Proceed by taking out the Fuel Level Sensor access panel bolts then disconnect the quick-connect fittings from the Fuel Level Sensor while separating electrical connectors from both the modular Fuel Level Sensor and the fuel tank pressure sensor. Tip the modular Fuel Level Sensor while removing it to protect the float operation and transfer remaining fuel to an authorized container. Remove the Fuel Level Sensor retaining ring by using Fuel Level Sensor lock nut wrench (J 39765) which will enable the modular Fuel Level Sensor to rise. Check and clean both o-ring sealing surfaces and position the new o-ring onto the fuel tank before confirming that the Fuel Pump Strainer remains straight and not obstructing the float arm movement. Install the Fuel Level Sensor and the retainer cam with the help of a Fuel Level Sensor lock nut wrench device (J 39765) before reconnecting quick-connect fittings along with electrical connectors to the fuel system. To verify the absence of leaks, follow the specified procedure of turning the ignition on and off while monitoring the battery connection state. Attach the Fuel Level Sensor access panel and fasten its bolts to 2 n.m (18 lb in) before installing the rear compartment floor trim. The last step involves installing the spare tire followed by the jack and spare tire cover then refueling the tank while installing its filler pipe cap. Finally, secure the rear seat cushion and intake manifold sight shield with 3 n.m (27 lb in) torque values.

The fuel sender support assembly will spring up.

Fuel Pressure Gauge (J 34730) and Fuel Sender Lock Nut Wrench (J 39765).