OEM 2004 Chevrolet Malibu Fuel Level Sensor

2004 Chevrolet Malibu Fuel Level Sensor Parts and Q&A

• Q: How to replace the Fuel Level Sensor assembly on 2004 Chevrolet Malibu?

  A: The j 45722 Fuel Level Sensor lock ring wrench alone should be used for disconnecting evap and fuel feed lines from the Fuel Level Sensor assembly to prevent damage to the lock ring. Secure the Fuel Tank to prevent rotation because only significant force will release the lock ring while handling of the Fuel Level Sensor assembly by fuel pipes must be avoided to maintain joint integrity. Apply the j 45722 to the Fuel Level Sensor lock ring followed by a long breaker-bar while rotating counterclockwise to unlock it then remove the Fuel Level Sensor assembly together with the seal and discard the seal. Wash the Fuel Level Sensor sealing areas while checking the lock ring for damage; change the lock ring if it shows warping greater than 0.41 mm (0.016 in). A new seal must be used for the Fuel Level Sensor assembly installation while the Fuel Pump Strainer remains horizontal and the float arm stays obstruction-free. Fit the Fuel Level Sensor assembly with the lock ring while utilizing the j 45722 tool to guide correct installation of clockwise rotation. The final step involves attaching the fuel feed along with evap lines to the sensor assembly then reinstalling the Fuel Tank.