GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Epica 🢒 Engine 🢒 Engine Controls - 2.0L (L34 GMDAT) 🢒 Fuel Sender Assembly Replacement

Removal Procedure

    Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the negative battery cable.
  3. Remove the rear seat. Refer to Rear Split Folding Seat Back Replacement in Seats.
  4. Remove the fuel pump access cover.
  5. Remove the fuel pump. Refer to Fuel Pump Replacement .

    6. Object Number: 1539061 Size: SH
  6. Disconnect the insulator connector.

    7. Object Number: 1539063 Size: SH
  7. Push the terminal wedge (1) in the insulator connector.

    8. Object Number: 1539066 Size: SH
  8. Push the wedge (1) outside and then pull the wires to disconnect from the insulator.

    9. Object Number: 1539069 Size: SH
  9. Remove the fuel level sensor (1) from the sender housing (2).
  10. Remove the sender housing (2).

    11. Object Number: 1539071 Size: SH
  11. Remove the fuel sender assembly (1).

Installation Procedure

    Object Number: 1539072 Size: SH
  1. Wind the wires (1) to the sender assembly (2).

    2. Object Number: 1539073 Size: SH

    Important: Failure to install the sender assembly correctly will result in inaccurate fuel gage reading.

  2. Install the sender assembly onto the fuel pump assembly (1).

    3. Important: Failure to install the fuel level sensor correctly will result in inaccurate fuel level warning lamp operation.

  3. Install the fuel level sensor onto the sender housing.

    4. Object Number: 1539074 Size: SH
  4. Connect the wires into the insulator connector as follows:
    5. • Connect wire (1), Red
    • Connect wire (2), Blue
    • Connect wire (3), Gray
    • Connect wire (4), Yellow
    • Connect wire (5), Blue
    • Connect wire (6), Black

    Object Number: 1539061 Size: SH
  5. Connect the insulator connector.
  6. Install the fuel pump. Refer to Fuel Pump Replacement .
  7. Install the fuel pump access cover.
  8. Install the rear seat. Refer to Rear Split Folding Seat Back Replacement in Seats.

    9. Caution: Refer to Battery Disconnect Caution in the Preface section.

  9. Connect the negative battery cable.