Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2008 Pontiac G5 L4-2.2LFACTORY OEM SERVICE PROCEDURE
Fuel Level Sensor Replacement (With RPO Code NU6)
Fuel Level Sensor Replacement (With RPO Code NU6)
Tools Required
J45722 Fuel Sender Lock Ring Wrench
Removal Procedure
Caution: Refer to Gasoline/Gasoline Vapors Caution.
Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.
1. Remove the fuel tank.
2. Using the J45722, unlock the fuel sender lock ring.
3. Slowly lift the fuel pump flange up until the quick connect fittings (1) and fuel level sensor electrical connector are just visible.
4. Disconnect the fuel level sensor electrical connector from the fuel pump flange.
5. Disconnect the fuel tank vent valve and the fuel filter quick connect fittings (1) from the fuel pump flange.
6. Remove the fuel pump flange lock ring (1) and fuel pump flange (2). If required, remove the lock ring from the flange.
7. Remove and discard the fuel pump flange seal (3).
8. Squeeze the sides of the fuel level sensor retainer (2) together in order to remove the fuel level sensor.
9. Remove the fuel level sensor from the fuel pump module by sliding the sensor up.
Installation Procedure
1. Position the fuel level sensor to the fuel pump module and slide the sensor down.
2. Ensure that the fuel level sensor retainer (2) is fully engages the fuel pump module.
3. Position a NEW fuel pump flange seal (3) onto the fuel tank.
4. If required, install the lock ring onto the flange. Position the fuel pump flange (2) and lock ring (1) over the fuel tank opening.
5. Ensure that the fuel pump flange tab is aligned with the arrow on the fuel tank.
6. Connect the fuel tank vent valve and the fuel filter quick connect fittings (1) to the fuel pump flange.
7. Connect the fuel level sensor electrical connector to the fuel pump flange.
8. Slowly lower the fuel pump flange into the fuel tank.
9. Using the J45722, lock the fuel sender lock ring.
10. Install the fuel tank.
Factory Service Tools
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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.
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