Tools Needed:
- Flat-head/Philips head screwdriver
- Safety glasses
- Pliers
- New fuel level sensor (for 99 Chevrolet Astro van, 19236777 or equivalent)
- Rubber gloves
Procedure:
1. Preparation:
- Put on safety glasses and rubber gloves for protection.
- To relieve any pressure in the gas tank, turn the ignition key to "ON" for a few seconds, then turn it back off without starting the engine. Repeat this process 2-3 times.
2. Locate the Fuel Tank:
- Open the gas tank cover.
- The fuel tank on a 99 Astro van is located beneath the driver's side rear of the vehicle.
3. Remove the Fuel Tank Access Cover:
- There is a plastic cover with bolts or screws securing it to the chassis just above the fuel tank.
- Remove these bolts or screws using the appropriate screwdriver.
- Take out the plastic access cover.
4. Disconnect the Electrical Connection:
- There will be an electrical connector attached to the fuel level sensor.
- Press down on the release mechanism and disconnect the electrical connection.
5. Remove Fuel Lines (Optional):
- Some models may require disconnecting fuel lines to remove the fuel sensor assembly.
- If this is the case, use a wrench to loosen the fuel line connections and allow fuel to drain into an appropriate container.
6. Remove the Fuel Level Sensor:
- Using a flat-head or Philips head screwdriver as needed, remove the screws or bolts securing the fuel level sensor to the fuel tank.
- Be careful not to drop any screws or bolts into the tank.
7. Take Out the Old Sensor:
- Once you have removed all the screws, gently lift out the old fuel level sensor and float assembly.
8. Install the New Sensor:
- Place the new fuel level sensor into the fuel tank.
- Fasten it securely with the screws or bolts you removed earlier.
9. Reconnect Electrical Connector:
- Reconnect the electrical connector you disconnected earlier to the new sensor.
10. Reconnect Fuel Lines (Optional):
- If you disconnected any fuel lines, reattach them and tighten the connections securely.
11. Test the Fuel Level Sensor:
- Turn the ignition to "ON" and observe the fuel gauge. It should now provide an accurate reading.
12. Replace the Access Cover:
- Reattach the plastic access cover that covers the fuel level sensor.
Note:
Ensure that all connections are secure and that there is no leakage before driving the vehicle. If you encounter any issues during the replacement or the fuel gauge still doesn't work, seek the assistance of a professional mechanic.
