GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Alero Export 🢒 Engine 🢒 Engine Controls - 3.4L 🢒 Fuel Level Sensor Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Remove the fuel tank. Refer to Fuel Tank Replacement .
  4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  5. Remove the fuel pump and fuel level sender electrical retaining clip at the top of the modular fuel sender assembly.
  6. Disconnect the fuel pump and fuel level sender electrical connector.

    7. Object Number: 619293 Size: SH
  7. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2).

    8. Object Number: 619296 Size: SH
  8. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing.
  9. Remove the retaining clip from the electrical connector.
  10. Remove the fuel level sender wires from the connector, taking care to note the location of the wires.

Installation Procedure

    Important: 

       â€¢ Make sure the wires are routed under the fuel level sender.
       â€¢ Make sure the tab locks in place.


    Object Number: 619296 Size: SH
  1. Install the fuel level sensor (1) by sliding it down in the housing.

    2. Object Number: 619293 Size: SH
  2. Slide the upper reservoir into the lower reservoir (2).
  3. Connect the 2 wires into the connector and lock it with the retaining clip.
  4. Connect the fuel pump and fuel level sensor electrical connector and lock with it the retaining clip.
  5. Reinstall the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  6. Reinstall the fuel tank. Refer to Fuel Tank Replacement .
  7. Refill the fuel tank.
  8. Reinstall the fuel fill cap.

    9. 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.

  9. Connect the negative battery cable.
  10. Inspect for leaks using the following procedure:
    11. 10.1. Turn ON the ignition for 2 seconds.
    10.2. Turn OFF the ignition for 10 seconds.
    10.3. Turn ON the ignition.
    10.4. Inspect for fuel leaks.