AutoZone | Repair Guides | Fuel System | Gasoline Fuel Injection | Fuel Level Sending Unit | AutoZone.com

Search suggestions

    My Vehicles

    Add a Vehicle

    Find a Store

    Select Store

    SAVE 20% ON ONLINE SHIP-TO-HOME ORDERS OF $100 OR MORE.

    Use Code: SEECLEAR

    See Details

    Malibu 2001-2005

    Fuel Level Sending Unit

    Print

    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove the fuel pump module assembly.
    4.  
    5. Release the fuel level sensor wiring harness from the molded-in tab on the pump module bowl.
    6.  
    7. Disconnect the fuel level sensor electrical connector from the pump module cover.
    8.  
    9. Depress the retaining tab on the sensor and begin to slide the level sensor away from the pump module.
    10.  
    11. Carefully slide the level sensor the rest of the way off of the pump module.

      Click image to see an enlarged view

      Fig. The removal and installation of the fuel level sensor-Malibu Maxx shown



      Click image to see an enlarged view

      Fig. The removal and installation of the fuel level sensor-Malibu Sedan shown

    12.  

    To install:

    1. Carefully slide the fuel level sensor into the slots on the fuel pump module bowl. Secure the retaining tab on the sensor into the slot on the pump module bowl.
    2.  
    3. Connect the fuel level sensor electrical connector to the pump module cover.
    4.  
    5. Install the fuel level sensor wiring harness to the molded-in tab on the pump module bowl.
    6.  
    7. Install the fuel pump module assembly.
    8.  

    Testing



    1. Ignition OFF , disconnect the harness connector at the fuel level sensor.
    2.  
    3. While sweeping the fuel level sensor through its full range of motion, test for a minimum value of less than 41 ohms and a maximum value greater than 119 ohms of resistance between signal terminal (2) and the low reference terminal (3).
    4.  
    5. If not within the specified range, replace the fuel level sensor.

      Click image to see an enlarged view

      Fig. Fuel level sender and pump electrical connector

    6.  

     
    AutoZone Logo