How do you replace a fuel level sensor in a 2004 impala?

Answer 1

You can access the pump/fuel send unit through an access panel in the floor of the trunk just behind the rear seat. The job will take about 1 hour. DO NOT SMOKE NEAR the car as there are lots of gas fumes. Try to do it when the tank is as close to empty as possible. My tank holds 17 gallons, but on my trip computer on the ceiling, I have calculated that a reading of 13.8 gallons used is an empty tank. I ordered a part on the web for $35. Here are step by step instructions:

1) Lower the two rear seats

2) The carpet in the trunk is split and held together with Velcro, peel it back revealing the access panel.

3) remove the 8 10mm quick-nuts and pry the access panel off the trunk floor

4) remove the two electrical connectors and tie a string around one of them so they don't fall between the underside of the trunk floor and the gas tank

5) remove the 3 fuel tubes. the one closest to the rear of the car has pressure so expect gas to shoot out. Be careful not to break the lock on the connectors, the two on the ends use a barbed type, the one in the middle must be compressed from the edges.

6)Using a flat head screwdriver and hammer, remove locking ring by rotating it counterclockwise. Before removing it fully mark the hook and slot with a white crayon or scratch it with the screwdriver so you will be able to realign the locking ring when you reinstall.

7) Slide the locking ring toward the fuel line connectors and lift the entire unit upward. it is about 4" in diameter and about 15" long. Be careful not to damage the filter at the base of the unit. Remember it is full of gasoline if you tip it, gas will pour out.

6) Bring the unit to a table and disconnect the connectors:

a) Power coupling for the pump, is at the base, pull side tabs outward to release the power coupling.

b) the electrical fitting at the top is held in with a red connector, using a screwdriver pry the red fitting out of the connector. Now the connector should be able to be removed. Move all wires from the fuel sensor out from inside the assembly and disconnect the purple wires from their lock on the housing

c) lastly remove the fuel sensor, it is held onto the housing of the assembly by a locking connector and a barbed fitting. Using the screwdriver, pry the locking tab downward toward the base of the housing. This will allow the barbed fitting to be compressed with a needle nose pliars. The part should now slide downward.

d) remove the old black gas tank gasket from the pump by sliding it downward and off the pump. Install the new gasket.

e) attach the float to the new part by attaching the end non-float end into the hole of the sensor and push the metal rod into the black connector until you hear a clipping sound.

f) reverse these directions to install the sensor onto the pump assembly.

7)Before reinstalling, check the filter at the bottom to make sure there are no tears or the filter does not look dirty. Also look into tank for dirt. This is a good time to clean it out if it is dirty.

8) reinstall the assembly into the tank. Move locking ring into position but do not secure; attach fuel lines, and line up ring with notch you made upon removal.

9) using a screwdriver tighten the locking ring and attach electrical connectors.

Turn key on, but wait 10 seconds for the pump to prime. Then start car. if all is well, replace the access panel with the 8 10 mm screws and fix the carpet.