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HOMESERVICE MANUALSCHEVROLET2012CHEVY EXPRESS G2500, VAN PASSENGER, 4.8L ENG VIN AREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 996 (ENGINE CONTROLS AND FUEL - 4.8L, 5.3L, 6.0L, 6.2L, OR 7.0L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL LEVEL SENSOR REPLACEMENT (15 EXT/CREW CAB W/26 GAL TANK)INSTALLATION PROCEDURE
2012 Chevrolet Chevy Express G2500, Van Passenger, 4.8L Eng VIN A

Installation Procedure

2012 Chevrolet Chevy Express G2500, Van Passenger, 4.8L Eng VIN ASECTION Installation Procedure
WARNING: This page is about a different car, the 2008 GMC Sierra, 2008 GMC Cab & Chassis Sierra, 2008 Chevrolet Silverado, and 2008 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Fuel Level Sensor
    GM1854697Courtesy of GENERAL MOTORS CORP.
  1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot.
    2. Fig 2: Sensor Clip & Retainers
    GM1854696Courtesy of GENERAL MOTORS CORP.
  2. Ensure that the fuel level sensor retainers (1) engage the module reservoir.
  3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires.
    4. Fig 3: Fuel Level Sensor Electrical Connectors
    GM1854694Courtesy of GENERAL MOTORS CORP.
  4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover.
  5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 gal Tank) .
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.