Fuel Level Sensor

This procedure replaces the fuel level sensor in the fuel tank by lowering the fuel tank, removing the fuel pump module, and replacing the sensor assembly.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — AC Delco 13502903 or equivalent
• Fuel pump module O-ring seal × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery terminal and wait 2 minutes
3. Siphon or drain fuel tank to less than 1/4 capacity using approved fuel transfer pump and storage container
4. Raise vehicle and support securely on jack stands at frame rail locations
5. Remove spare tire if stored underneath vehicle to improve access

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump fuse in the underhood fuse box (typically labeled ECM 1 or FUEL PUMP). Remove the fuse, then attempt to start the engine. Let it run until it stalls, then crank for an additional 3 seconds to ensure pressure is relieved. Turn ignition off.
2. 2

   Disconnect fuel filler hose and EVAP lines
   Locate the fuel filler neck at the rear quarter panel. Loosen the hose clamp securing the rubber filler hose to the fuel tank inlet. Slide clamp back and twist hose to break it free. Disconnect the EVAP vent line and fresh air hose from the tank using the quick-disconnect tool by pressing the release tabs.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect fuel feed and return lines
   Locate the fuel feed and return hard lines at the front of the fuel tank. Using the appropriate fuel line disconnect tool, press the release tabs on the quick-connect fittings and pull the lines straight off. Cap or plug the lines to prevent contamination. Have shop towels ready to catch residual fuel.
   ⚠Residual fuel will drain from lines. Have drain pan and shop towels ready.
4. 4

   Disconnect electrical connectors
   Locate the fuel pump module electrical connector on top of the fuel tank (accessible from underneath). Press the release tab and disconnect the main harness connector. If equipped with a fuel tank pressure sensor, disconnect that connector as well.
5. 5

   Support fuel tank
   Position a transmission jack or fuel tank support jack under the center of the fuel tank. Raise jack until it contacts tank and supports the weight, but does not lift the tank. Use a piece of wood between jack and tank to distribute load and prevent damage.
6. 6

   Remove fuel tank shield and straps
   Remove the fuel tank shield bolts (if equipped) using a 13mm socket. Remove the two fuel tank strap mounting bolts at the rear of each strap using a 15mm socket. Pivot the straps down and away from the tank while supporting tank with jack.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
7. 7

   Lower fuel tank
   Carefully lower the transmission jack to drop the fuel tank approximately 6-8 inches. Ensure all lines and electrical connections are clear. Verify tank is stable on jack before proceeding. You do not need to fully remove the tank.
8. 8

   Remove fuel pump module lock ring
   Clean debris from around the fuel pump module cover on top of tank. Using the lock ring tool, rotate the fuel pump module lock ring counterclockwise to unlock. Remove the lock ring completely. Note the orientation of the module before removal.
   ⚠Clean area thoroughly before opening tank to prevent debris from entering fuel system.
9. 9

   Remove fuel pump module
   Carefully lift the fuel pump module straight up and out of the tank. Tilt the module slightly to maneuver the fuel level sensor float arm out of the tank opening. Have a drain pan ready as fuel will drain from the module reservoir. Place module in clean drain pan.
10. 10

    Replace fuel level sensor
    On the workbench, locate the fuel level sensor on the side of the pump module. Disconnect the electrical connector from the sensor. Release the retaining clip or tabs securing the sensor to the module housing. Slide the fuel level sensor and float arm assembly out. Install new sensor by reversing removal, ensuring the float arm moves freely through its full range of motion and connector clicks securely.
11. 11

    Install fuel pump module
    Install new O-ring seal on top of fuel tank (discard old seal). Lubricate new O-ring lightly with clean engine oil. Carefully lower fuel pump module into tank opening, aligning orientation marks noted during removal. Ensure float arm does not bind. Press module down until it seats against O-ring.
    ℹ️Ensure fuel level sensor float arm is positioned correctly and does not contact tank walls during installation.
12. 12

    Install lock ring
    Position the lock ring over the fuel pump module and rotate clockwise using the lock ring tool until it locks into place. Verify the lock ring is fully seated and engaged in the locking tabs.
13. 13

    Raise and secure fuel tank
    Reconnect the fuel pump module electrical connector and any tank pressure sensor connectors. Raise the fuel tank into position using the transmission jack. Align tank with strap mounting locations. Install fuel tank straps and torque mounting bolts to specification. Install shield if equipped.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
14. 14

    Reconnect fuel and EVAP lines
    Install new O-rings on fuel line fittings. Push fuel feed and return lines onto tank fittings until they click into place. Tug on lines to verify secure connection. Reconnect EVAP vent and fresh air hoses. Reconnect fuel filler hose and install hose clamp, torquing to specification.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)

    Hose Clamps3 Nm (2 lb-ft)

Reassembly

1. Reinstall spare tire if removed
2. Reconnect negative battery terminal
3. Reinstall fuel pump fuse
4. Lower vehicle from jack stands

Verification

• Add fuel to tank (minimum 3 gallons) to ensure pump is submerged
• Turn ignition to ON position (do not start) for 5 seconds, then OFF. Repeat 3 times to prime fuel system
• Inspect all fuel line connections and tank area for leaks
• Start engine and verify it runs normally without fuel delivery issues
• Check instrument cluster fuel gauge reading - it should reflect actual fuel level accurately
• Drive vehicle and verify fuel gauge moves appropriately as fuel is consumed
• Re-inspect all connections for leaks after test drive

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