OEM 2005 Chevrolet Monte Carlo Fuel Level Sensor

2005 Chevrolet Monte Carlo Parts Questions & Experts Answers

• Q: How to replace the Fuel Level Sensor assembly on 2005 Chevrolet Monte Carlo?

  A: Changing the Fuel Level Sensor assembly begins with reducing fuel system pressure while ventilating the area to prevent dangerous fuel vapor fires. Each connection between hoses and the fuel pipe needs cleaning followed by quick fitting caps to prevent contamination. Start by draining the Fuel Tank while elevating the vehicle and unclamping the Fuel Filler Hose at the Fuel Tank prior to removing the hose. The quick-fittings on the Fuel Tank need disconnection for evap and return fuel pipe and fuel feed pipe. Afterward, remove the Exhaust Pipe hangers to lower the complete exhaust system. Disconnect the evap fresh air line at the splice point while removing both Fuel Tank shield push pins and the shield itself. Then apply support to the Fuel Tank with a proper jack. Open the Fuel Tank strap bolts and extract the Fuel Tank from the vehicle to a dedicated work place. Begin by disconnecting the electrical connectors holding the Fuel Level Sensor along with the Fuel Pressure Sensor before cleaning both fuel pipes and the sensor assembly. Proceed to break loose the quick-connect fittings at the sensor assembly. The Fuel Level Sensor retaining ring should be removed carefully because it will make the modular Fuel Level Sensor assembly spring upward so that the sensor assembly can be taken out. The new Fuel Level Sensor assembly seal must be positioned into the Fuel Tank after conducting surface inspections and cleaning operations on the sealing areas. Follow these steps to install the Fuel Level Sensor assembly while verifying that neither the pump strainer gets twisted nor the retaining snap ring loses its proper seating. After connecting both electrical and quick-connect fittings for the sensor and pressure sensor you should lift the Fuel Tank into position then fasten its strap bolts with 48 n.m (35 lb ft) torque. Secure the tank shield into place using push pins while connecting the fuel feed pipe, return pipe and evap pipe, then install the Fuel Filler Hose and tighten its clamp to 2.5 n.m (22 lb in). After raising the exhaust system users should install hangers before lowering the vehicle while adding fuel and setting the fuel filler pipe cap. Reconnect the negative Battery Cable while performing a leak test through a systematic irrigation of the ignition at the appropriate sequence.