OEM 2008 Chevrolet Malibu Fuel Level Sensor

2008 Chevrolet Malibu Fuel Level Sensor Parts and Q&A

• Q: How to replace the Fuel Level Sensor assembly on 2008 Chevrolet Malibu?

  A: The first step to replace the Fuel Level Sensor assembly requires removing the Fuel Tank and disconnecting the Fuel Tank Fuel Pump module wiring harness electrical connectors (1, 2) from the Fuel Pressure Sensor and the module as well as separating the Fuel Tank vent pipe quick connect fittings (3, 4) from the module. The j 45722 Fuel Level Sensor lock ring wrench (J 45722) should be used to fit onto the Fuel Pump module lock ring while taking care to protect it from damage. Secure the Fuel Tank to avoid its rotation instead of using impact tools. Also avoid touching the Fuel Level Sensor assembly near the fuel pipes because it may damage the joint. To unlock the lock ring using the j 45722 wrench and a long breaker-bar users must rotate it counterclockwise before removing the j 45722 tool. You should raise the Fuel Pump module slightly to release the Fuel Tank vent pipe quick connect fitting from the module cover before lifting it from the Fuel Tank while tilting the sensor arm to clear the float away from the route efficiently. Remove both the Fuel Pump module seal along with any old gaskets and then thoroughly clean the surfaces where seals attach. You should drain the fuel from the Fuel Level Sensor assembly through an approved fireproof container because of safety needs. The Fuel Pump module needs a lock ring replacement when it shows signs of damage or lack of flatness. Clean male pipe ends on the Fuel Pump module before installing a fresh Fuel Tank module seal on the Fuel Tank and inserting the module while letting the sensor arm and float pass through the opening. Lower the module to attach the Fuel Tank vent pipe quick connect fitting before connecting the fitting to the module cover then push the module down to its position. Lock down the j 45722 on the Fuel Pump module lock ring with clockwise rotation while directing its correct side toward the top. After removing j 45722, install both Fuel Tank vent pipe quick connect fittings (3, 4) to the module followed by attaching the Fuel Pressure Sensor connector (1) and the module connector (2) to their corresponding wiring harnesses before reattaching the Fuel Tank.