Skip to content
Tahoe / Yukon Service Manual

Fuel Level Sensor Replacement (Short Wheelbase)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5539502 Single Use Fasteners and Components Fuel Sender Seal Special Tools CH-45722 Fuel Sender Lock Ring Wrench Equivalent regional tools: Special Tools

  1. Relieve the fuel system pressure. Fuel Pressure Relief
  2. Drain the fuel tank. Fuel Tank Draining
  3. Raise and support the vehicle. Lifting and Jacking the Vehicle
Fuel Level Sensor Replacement (Short Wheelbase) — figure 1
Fuel Level Sensor Replacement (Short Wheelbase) — figure 1
  1. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Remove [4x]
  2. Remove both rear stabilizer shaft clamp  (2) from the frame and let the stabilizer shaft hang.
Fuel Level Sensor Replacement (Short Wheelbase) — figure 2
Fuel Level Sensor Replacement (Short Wheelbase) — figure 2
  1. Evaporative Emission Hose (1) » Disconnect [2x] — Plastic Collar Quick Connect Fitting Service
Fuel Level Sensor Replacement (Short Wheelbase) — figure 3
Fuel Level Sensor Replacement (Short Wheelbase) — figure 3
  1. Fuel Feed Hose (1) @ Fuel Feed Pipe (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Level Sensor Replacement (Short Wheelbase) — figure 4
Fuel Level Sensor Replacement (Short Wheelbase) — figure 4
  1. Fuel Tank Filler Hose Clamp (1) » Loosen
  2. Fuel Tank Filler Hose (2) » Remove
  3. Evaporative Emission Hose (3) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Level Sensor Replacement (Short Wheelbase) — figure 5
Fuel Level Sensor Replacement (Short Wheelbase) — figure 5
  1. Fuel Tank Filler Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Level Sensor Replacement (Short Wheelbase) — figure 6
Fuel Level Sensor Replacement (Short Wheelbase) — figure 6
  1. Place a suitable adjustable jack under the fuel tank.
  2. Strap fuel tank to jack.
  3. Fuel Tank Strap Bolt (1) » Remove [2x]
  4. Fuel Tank Strap (2) » Remove [2x]
Fuel Level Sensor Replacement (Short Wheelbase) — figure 7
Fuel Level Sensor Replacement (Short Wheelbase) — figure 7
  1. Lower the fuel tank, allowing clearance to access connections at the top of the tank.
  2. Electrical Connector (1) » Disconnect [3x]
  3. Fuel Feed Hose Clip (2) » Disengage
  4. Wiring Harness Retainer (3) » Disengage
Fuel Level Sensor Replacement (Short Wheelbase) — figure 8
Fuel Level Sensor Replacement (Short Wheelbase) — figure 8
  1. Fuel Tank (1) » Remove
Fuel Level Sensor Replacement (Short Wheelbase) — figure 9
Fuel Level Sensor Replacement (Short Wheelbase) — figure 9
  1. Evaporative Emission Canister Vent Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
  2. Evaporative Emission Canister Vent Hose (2) » Reposition
Fuel Level Sensor Replacement (Short Wheelbase) — figure 10
Fuel Level Sensor Replacement (Short Wheelbase) — figure 10
  1. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Disengage [2x]
  2. Fuel Feed Hose @ Fuel Tank Fuel Pump Module (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
  3. Fuel Feed Hose (2) » Reposition
Fuel Level Sensor Replacement (Short Wheelbase) — figure 11
Fuel Level Sensor Replacement (Short Wheelbase) — figure 11
  1. Fuel Feed Hose @ Fuel Tank Fuel Pump Module (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
  2. Fuel Tank Filler Vent Hose (2) » Reposition
Fuel Level Sensor Replacement (Short Wheelbase) — figure 12
Fuel Level Sensor Replacement (Short Wheelbase) — figure 12
  1. Fuel Sender Retainer(1) » Remove — CH-45722 Fuel Sender Lock Ring Wrench(2)
Fuel Level Sensor Replacement (Short Wheelbase) — figure 13
Fuel Level Sensor Replacement (Short Wheelbase) — figure 13
  1. Fuel Tank Vent Valve Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Level Sensor Replacement (Short Wheelbase) — figure 14
Fuel Level Sensor Replacement (Short Wheelbase) — figure 14
  1. Fuel Tank Fuel Pump Module (1) » Remove
  2. Fuel Sender Seal (2) » Remove and DISCARD
Fuel Level Sensor Replacement (Short Wheelbase) — figure 15
Fuel Level Sensor Replacement (Short Wheelbase) — figure 15

  1. Disconnect the fuel level sensor electrical connector.

  2. Fuel Level Sensor (1) » Remove Installation Procedure

  3. Fuel Level Sensor (1) » Install

  4. Connect the fuel level sensor electrical connector.

  5. Fuel Sender Seal (2) » Install NEW

  6. Fuel Tank Fuel Pump Module (1) » Install

  7. Fuel Tank Vent Valve Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

  8. Fuel Sender Retainer(1) » Install — CH-45722 Fuel Sender Lock Ring Wrench(2)

  9. Fuel Tank Filler Vent Hose (2) » Reposition

  10. Fuel Tank Filler Vent Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

  11. Fuel Feed Hose (2) » Reposition

  12. Fuel Feed Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

  13. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Engage [2x]

  14. Evaporative Emission Canister Vent Hose (2) » Reposition

  15. Evaporative Emission Canister Vent Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

  16. Place a suitable adjustable jack under the fuel tank.

  17. Strap fuel tank to jack.

  18. Raise the fuel tank  (1), allowing clearance to access connections at the top of the tank.

  19. Wiring Harness Retainer (3) » Engage

  20. Fuel Feed Hose Clip (2) » Engage

  21. Electrical Connector (1) » Connect [3x]

  22. Raise the tank to the installed position.

  23. Fuel Tank Strap (2) » Install [2x]

  1. Fuel Tank Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications

  2. Fuel Tank Filler Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

  3. Evaporative Emission Hose (3) » Connect — Plastic Collar Quick Connect Fitting Service

  4. Fuel Tank Filler Hose (2) » Install

  5. Fuel Tank Filler Hose Clamp (1) » Tighten — Fastener Specifications

  6. Fuel Feed Hose (1) @ Fuel Feed Pipe (2) » Connect — Plastic Collar Quick Connect Fitting Service

  7. Evaporative Emission Hose (1) » Connect [2x] — Plastic Collar Quick Connect Fitting Service

  8. Raise rear stabilizer shaft into installed position.

  9. Rear Stabilizer Shaft Clamp (2) » Install [2x]

  10. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Install and tighten [4x] — Fastener Specifications

  11. Lower the vehicle.

  12. Refill the fuel tank.

  13. Inspect for fuel leaks.