Camaro, Firebird, 1999 - 2002

Fuel Level Sensor

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  4.  
  5. Remove the fuel tank.
    WARNING
    Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

  6.  
  7. Remove the following components of the fuel sender assembly:

    Retaining ring
     
    Fuel sender assembly
     
    Gasket and discard
     

  8.  
  9. Clean the gasket sealing surfaces.

    Click image to see an enlarged view

    Fig. Fuel sender location-3.8L engine

  10.  

To install:


CAUTION
In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

  1. Position the new gasket on the fuel tank.
    NOTE
    The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

  2.  
  3. Carefully fold the strainer to allow the strainer to fit through the opening in the fuel tank. Make sure the strainer unfolds once it is placed in the tank.
  4.  
  5. Install the fuel sender assembly into the fuel tank.
  6.  
  7. Install the fuel sender retaining ring.
  8.  
  9. Install the fuel tank.
  10.  
  11. Reconnect negative battery cable.
  12.  

5.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  4.  
  5. Remove the fuel tank.
  6.  
  7. Disconnect the fuel feed pipe, the fuel return pipe and the EVAP pipe from the fuel sender.
  8.  
  9. Disconnect the fuel sender electrical connectors from the fuel sender.
  10.  
  11. Remove the fuel sender assembly retaining ring.
    WARNING
    Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

  12.  
  13. Remove the fuel sender assembly.
    CAUTION
    Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.

  14.  
  15. Remove the fuel sender seal and discard.

    Click image to see an enlarged view

    Fig. Location and removal of fuel sender-5.7L engine

  16.  

To install:


CAUTION
In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

  1. Clean the seal sealing surfaces.
    WARNING
    With extreme care align the fuel sender seal in the fuel tank groove. Properly align the tab on the fuel sender in the notch on the fuel tank. Misalignment of the fuel sender seal or the fuel sender could damage the fuel tank sender tabs. Replace the fuel tank if the fuel tank fuel sender tabs are damaged.

  2.  
  3. Install the new fuel sender seal on the fuel tank.
    NOTE
    The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

  4.  
  5. Install the fuel sender assembly into the fuel tank.
  6.  
  7. Install the fuel sender assembly retaining ring.
  8.  
  9. Perform fuel tank leak check.
  10.  
  11. Connect the fuel sender electrical connectors to the fuel sender.
  12.  
  13. Connect the fuel feed pipe, the fuel return pipe and the EVAP pipe to the fuel sender.
  14.  
  15. Install the fuel tank.
  16.  
  17. Reconnect negative battery cable.
  18.  

 
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