Mechanics

99 FUEL LEVEL SENDER UNIT INSTALL

1999 Pontiac Grand Am • 4 cylinder FWD Automatic • 166,500 miles

I have a 99 grand am 4 cyl. The fuel gauge is not working properly. I am looking at an universal fuel sender unit and aftermarket fuel gauge as replacements.
I am wondering what the process for making those changes are and if it would be worth it to do the work myself, also about how long it would take.
The parts i'm looking at to use are a Sunpro/240 Ohm empty and 33 Ohm full fuel level sender, and a Sunpro/2 1/16 in. 240 Ohm empty / 33 Ohm full black face electric fuel level gauge.
I know it will be a lot cheaper for my to do the work myself as I have some knowledge of mechanics.
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Myname2617
February 26, 2011.




I would stick with a factory replacement not a universal a lot less work and you would at least know when the job was done you would haven't to possibly take it apart again.I posted removing the fuel tank and replacing the sending unit.Did you test to see if you had a bad sending unit or are you guessing?Also here is a a/c delco sending unit i found for your car here is the link.Not that hard to change if your used to working on car's.Let me know how it come's out.

http://www.amazon.com/ACDelco-SK1189-Fuel-Tank-Sensor/dp/B000IZ5F1G/ref=au_pf_pfg_s?ie=UTF8&Model=Grand%20Am|596&n=15684181&s=automotive&Make=Pontiac|52&Year=1999|1999&newCar=1&carId=020

1. Disconnect the negative battery cable.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

3. Raise the vehicle and suitably support.
4. Grasp the nylon fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for the other nylon fuel pipe quick-connect fitting.

CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.

5. Using compressed air, blow out dirt from the quick-connect fittings at end of the fuel pipes.
6. Disconnect the quick-connect fitting at the fuel filter.

7. Remove the quick connect fittings at the end of the fuel pipe and vapor pipes.

9. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear suspension.
10. Remove the heat shield.
11. Remove the hoses at tank from filler, vent and vapor pipes.
12. With the aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps.

13. With the aid of an assistant, lower the fuel tank.
14. Remove the fuel tank pressure sensor electrical connector.
15. Remove the fuel sender electrical connector.
16. Remove the tank from the vehicle.
17. Remove the fuel sender assembly from the tank.

INSTALLATION PROCEDURE

IMPORTANT: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel pipe O-rings for cuts, nicks, swelling or distortion. Replace if necessary.

1. Install the fuel sender assembly to tank.
2. With the aid of an assistant, raise the fuel tank (1) to body.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the fuel tank retaining straps.

Tighten
Tighten the bolts to 35 N.m (26 lb ft) .

4. Install the fuel tank pressure sensor electrical connector.
5. Install the fuel tank sender electrical connector.
6. Install the hoses to filler, vent and vapor pipes
7. Install the heat shield.
8. Install the exhaust rubber hangers.

NOTE: Refer to Fastener Notice in Service Precautions.

9. Install the muffler support bolts.

Tighten
Tighten the bolt to 15 N.m (11 lb ft) .

CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings in order to reduce the risk of fire and personal injury.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

10. Install the nylon fuel pipe and fuel filter quick-connect fittings.
11. Lower the vehicle.
12. Refill the tank.
13. Connect the negative battery cable.
14. Inspect for fuel leaks through the following steps:

14.1. Turn the ignition switch to the ON position for two seconds .
14.2. Turn the ignition switch to the OFF position for ten seconds .
14.3. Turn the ignition switch to the ON position
14.4. Check for fuel leaks.

REMOVAL PROCEDURE

1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove the fuel tank.
4. Remove the modular fuel sender assembly.
5. Remove the fuel level sensor from the modular fuel sender.

INSTALLATION PROCEDURE

1. Install the fuel level sensor to modular fuel sender.
2. Install the fuel sender assembly.
3. Install the fuel tank.
4. Refill the fuel tank.
5. Connect the negative battery cable.
6. Inspect for fuel leaks through the following steps:

6.1. Turn the ignition switch to the ON position for two seconds .
6.2. Turn the ignition switch to the OFF position for ten seconds .
6.3. Turn the ignition switch to the ON position
6.4. Check for fuel leaks.

Saturntech9
Feb 27, 2011.
I'm just guessing that the sending unit is the problem. I just got the car a few days ago. The closest shop or auto parts store that I trust is about 45 miles away (the joys of living in a small town) I was just wanting to find out how much work it was gonna be before I start ordering parts.
Its still gonna be at least a few weeks before I have the money to do any of the work so i'm checking prices and amount of work of possible problems. And according to my research so far this seems to be the most likely problem.

Tiny
Myname2617
Feb 27, 2011.
If you replace the sender I would get the one I gave you the link to. So what is the fuel gauge doing?
AD

Saturntech9
Feb 27, 2011.
The fuel gauge bounces from full to empty at random times, whether driving or just idling. I just put $20 in gas in last night and the gauge seemed to be accurate for a while, then it dropped to empty and back to where it should be.

Tiny
Myname2617
Feb 27, 2011.
I found a bulletin that will help you with your problem check it out.
File In Section: 6E - Engine Fuel & Emission

Bulletin No: 83-63-20

Date: October, 1998
Subject: Inaccurate/Fluctuating Fuel Gauge Reading
(Replace Fuel Level Sensor)

Models: 1999 Oldsmobile Alero
1999 Pontiac Grand Am

Built Prior to the Following VIN Breakpoints: Model Location VIN Breakpoints

Alero Lansing Plant C XC310439
Grand Am Lansing Plant C XC523682
Lansing Plant M XM771844

Condition

Some customers may comment that the fuel gauge reads empty when tank is full; and/or are experiencing erratic fuel gauge readings.

Cause

Usage of certain fuel formulations may result in high resistance outputs from the fuel level sensor, resulting in erroneous fuel gauge readings.

Correction

Replace the existing ceramic fuel level sensor with service kit (P/N 25317985), following the instructions provided in the kit and those found in the applicable Service Manual.

Parts Information

P/N Description

25317986 Kit, Fuel Level Sensor

Parts are currently available from GMSPO.

Warranty Information

For vehicles repaired under warranty, use: Labor Operation Description Labor Time

L1197 Sensor, Fuel Level - 1.2 hrs
Replace

Saturntech9
Feb 28, 2011.

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