OEM 2005 Chevrolet Corvette Fuel Level Sensor

2005 Chevrolet Corvette Parts Questions & Experts Answers

• Q: How to replace the Fuel Level Sensor assembly on the right side on 2005 Chevrolet Corvette?

  A: The process of replacing the right side Fuel Level Sensor requires beginning by disconnecting the negative Battery Cable followed by right Fuel Tank removal to a proper working surface. Separate three main connections which include the evaporative emission (EVAP) purge line and the Fuel Pump module harness connector and the Fuel Tank pressure (FTP) sensor harness connector. Removing the ftp sensor becomes necessary if you replace the Fuel Pump module so disconnect the jet line insert connector from the crossover tube to the Fuel Tank opening. The Fuel Level Sensor lock ring tool (J39765-A) allows you to uninstall the Fuel Pump module locking ring but remember that the module springs up due to its spring action. Pull out the Fuel Pump module from the Fuel Tank after detaching the jet lines without harming the Fuel Level Sensor float arm. Take note of the jet line quick-connect connector positions before you detach these connections from the Fuel Pump module and extract the Fuel Pump module o-ring from the Fuel Tank opening. The crossover tube and Fuel Tank opening receive the jet line insert with new o-ring to install through its pathway. Assess jet line insert damage before selecting a replacement unit as required. Connect the jet line quick-connectors through the pump module opening in the correct positions as previously noted while ensuring proper latching of each connector. When installing the pump module into the Fuel Tank keep the float arm free of damage while using the Fuel Level Sensor lock ring tool (J39765-A) to correctly place the lock ring. Workers should utilize the Fuel Level Sensor lock ring tool (J39765-A) to achieve a full lock of the Fuel Pump module lock ring. Check the Fuel Pump module resistance values using a dmm when the tank is upside down using opposite vertex probe method for full and empty readings. The device should display 250 ohms for the full tank reading yet only 40 ohms during the empty tank condition. Securely connect the crossover tube you would use for the jet line insert between the Fuel Tank opening also. Placing the ftp sensor into position requires connector attachment of the ftp sensor harness followed by connections of the Fuel Pump module harness and the evap purge line from the Fuel Pump module prior to right Fuel Tank installation.