OEM 2005 Cadillac XLR Fuel Level Sensor

2005 Cadillac XLR Parts Questions & Experts Answers

• Q: How to replace the Fuel Level Sensor on the left side on 2005 Cadillac XLR?

  A: Begin the replacement of the left-side Fuel Level Sensor by disconnecting the negative cable of the battery followed by left Fuel Tank removal onto an appropriate work surface. Three components must be disconnected for the task including the Fuel Pump jumper harness from the Fuel Pump module along with the jet line insert connector from the crossover tube to the Fuel Tank opening and the fuel feed line from its welded clip on the Fuel Tank side. You can remove the Fuel Pump module locking ring by employing the fuel sender lock ring tool (J39765-A) because the module operates with spring force that lifts it upward when the ring is unscrewed. Pull out the Fuel Pump module from the Fuel Tank while jet lines remain attached to maintain a safe removal of the fuel sender float arm. Disconnect the quick-connect connectors from the Fuel Pump module inner port and take the jet line out of the module retainer cup before extracting the Fuel Pump module o-ring from the Fuel Tank opening. Pull out the jet line insert from the crossover tube into the Fuel Tank opening. Check the jet line insert for possible damage. If present replace it before you pass it through the crossover tube to reach the Fuel Tank opening. A new o-ring should be installed to the Fuel Tank opening before taping the jet line with the connector exposed during Fuel Pump module insertion. After inserting the pump module to the midway point in the Fuel Tank avoid striking the float arm while following the tape to gently draw the jet line up through the Fuel Pump module opening. Insert the jet line alone into the module retainer cup after which you should set it into the retaining clip. Use a connector to detach the jet line tape and join the quick-connect connectors of the jet line to the Fuel Pump module inner port while verifying complete connector latching. Fit the compressed Fuel Pump module into the Fuel Tank with attention to protecting the float arm before setting the Fuel Pump module lock ring. You need the fuel sender lock ring tool (J39765-A) to perform a complete locking process of the Fuel Pump module lock ring. Our tasks include connecting the fuel supply line to the weld clip on the Fuel Tank side then testing the Fuel Pump module values at minimum and maximum tank levels by inverting the container with a digital multi-meter to evaluate resistance rates (40 ohms at empty yet 250 ohms at full). The jet line insert connector gets connected to the crossover tube near the Fuel Tank opening after performing proper attachment. Then connect the Fuel Pump jumper harness to the Fuel Pump module followed by left Fuel Tank installation.