GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Express 🢒 Body 🢒 Wiring Systems 🢒 Fuel Level Sensor Replacement

Removal Procedure

    Object Number: 371000 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Remove the fuel tank. Refer to Fuel Tank Replacement .
  5. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  6. Disconnect the fuel pump electrical connector (5).
  7. Remove the electrical connector retaining clip (6) from the fuel level sensor .
  8. Disconnect the electrical connector (7) from the fuel level sensor under the fuel sender cover.
  9. Remove the retaining clip (4) from the fuel level sensor .
  10. Squeeze the locking tangs and remove the fuel level sensor (3).

Installation Procedure

    Object Number: 371000 Size: SH
  1. Install the fuel level sensor (3).
  2. Install the retaining clip (4) to the fuel level sensor .
  3. Connect the electrical connector (7) to the fuel level sensor .
  4. Connect the electrical connector retaining clip (6) to the fuel level sensor .
  5. Connect the fuel pump electrical connector (5).
  6. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  7. Install the fuel tank. Refer to Fuel Tank Replacement .
  8. Refill the fuel tank.
  9. Install the fuel filler cap.
  10. Connect the negative battery cable.
  11. Inspect for leaks:
    12. 11.1. Turn ON the ignition for 2 seconds.
    11.2. Turn OFF the ignition for 10 seconds.
    11.3. Turn ON the ignition .
    11.4. Inspect for fuel leaks.