Chevrolet 13512503 Fuel Level Sensor Assembly

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Remove the fuel pump/fuel level sensor module by first placing it on a clean workbench. Disengage the fuel level sensor wiring harness from the molded-in harness guide and disconnect the fuel level sensor electrical connector from the pump module cover. Depress the locking tab at the top inner side of the sensor and slide it downward off the fuel pump module.

To remove the fuel pump/fuel level sensor module, start by placing it on a clean workbench. Then, pry both locking tabs outward and slide the sensor up and off of the fuel pump module. For 2015 and earlier models (and 2016 Malibu Limited), use a pick to remove the electrical terminals from the fuel level sensor. For 2016 and later models (except Malibu Limited), disconnect the electrical connector from under the top of the module housing. To install the fuel level sensor on the fuel pump module, insert the terminals and slide the sensor unit into place until you hear a click. Gently pull on the sensor unit to verify that it's locked into place. The installation process is otherwise the reverse of the removal steps.

Using large water pump pliers, unscrew the fuel pump/fuel level sending unit module locknut counterclockwise. If the locknut is tight, use a hammer and brass punch to loosen it, avoiding steel punches that could produce sparks.

Remove the high-pressure fuel pump mounting bolts and the pump itself, replacing the bolts and O-ring with new ones.

If the fuel pressure is too high, the fuel pressure regulator should be replaced.

Disconnect the electrical connector, fuel supply line, and EVAP hoses from the fuel pump/fuel level sending unit module, making sure to soak up any spilled fuel with a shop rag.

Start by relieving the system fuel pressure and equalizing tank pressure by removing the fuel filler cap.

After the pump installation, the remaining steps of the removal process should be reversed.