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Home >> Cadillac >> 2005 >> XLR >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Introduction >> Repair Instructions >> Fuel Level Sensor Replacement - Left >> Installation Procedure
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Installation Procedure

  1. Inspect the jet line insert for damage and replace if necessary.
  2. Install the jet line insert through the crossover tube to fuel tank opening.
  3. Install a new fuel pump module O-ring to the fuel tank opening.
  4. Place tape around the jet line with the connector. This will permit line access once the pump module is inserted into the fuel tank.
    5. Fig 1: View Of Fuel Tank Module - Left
    GM904463Courtesy of GENERAL MOTORS CORP.
  5. Install the pump module into the fuel tank half way, taking care not to damage the float arm.
  6. Using the tape as a guide, gently pull the jet line up through the fuel pump module opening.
  7. Place the jet line with no connector in the module retainer cup.
  8. Secure the line into the module retaining clip.
  9. Remove the tape from the jet line with a connector.
    10. IMPORTANT: Pull on each connector to ensure that the connectors are properly latched.
  10. Connect the jet line quick-connect connectors to the fuel pump module inner port.
  11. Compress and align the fuel pump module into the fuel tank, while taking care not to damage the float arm.
  12. Install the fuel pump module lock ring.
  13. Using the J39765-A , fully lock the fuel pump module lock ring in place.
  14. Connect the fuel supply line into the weld clip on the side of the fuel tank.
  15. Using a DMM, verify the full and empty readings resistance reading of the fuel pump module. Turn the fuel tank upside down to achieve the full tank reading.

    Resistance: 

    • Empty tank reading 40 Ω resistance
    • Full tank reading 250 Ω resistance

    16. IMPORTANT: Pull the jet line insert connector to ensure that the insert is properly attached.
  16. Connect the jet line insert connector into the crossover tube to fuel tank opening.
    17. Fig 2: View Of Crossover Tube To Fuel Tank O-Rings & Alignment Feature
    GM903547Courtesy of GENERAL MOTORS CORP.
  17. Connect the fuel pump jumper harness to the fuel pump module.
  18. Install the left fuel tank. Refer to Fuel Tank Replacement - Left .
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