GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Epica 🢒 Engine 🢒 Engine Controls - 2.5L (LBK) 🢒 Fuel Level Sensor Replacement

Removal Procedure

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

  1. Remove the Fuel Sender Assembly. Refer to Fuel Sender Assembly Replacement .

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

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

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

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

    7. Object Number: 1539071 Size: SH
  7. Remove the fuel level sensor (1).

Installation Procedure

    Object Number: 1539072 Size: SH
  1. Wind the wires (1) to the fuel level sensor (2).

    2. Object Number: 1539073 Size: SH

    Important: Failure to install the fuel level sensor correctly will result in inaccurate fuel gage reading.

  2. Install the fuel level sensor onto the fuel sender assembly (1).

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


    Object Number: 1539074 Size: SH
  3. Connect the wires into the insulator connector as follows:
    4. • 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
  4. Connect the insulator connector.
  5. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .