Safety First:
* Disconnect the negative battery terminal before you start working. This prevents accidental shorts and sparks near flammable fuel.
* Work in a well-ventilated area. Fuel fumes are dangerous.
* Wear safety glasses to protect your eyes.
* Use jack stands if you need to lift the truck. Never work under a vehicle supported only by a jack.
Steps:
1. Locate the Fuel Tank: The fuel tank is located under the truck bed.
2. Access the Fuel Tank: You'll likely need to drop the fuel tank to access the fuel level sensor. This usually involves:
* Lowering the fuel tank: This may require disconnecting the fuel lines, electrical connectors, and the tank straps. You might need to support the tank with a jack or straps while disconnecting the lines.
* Getting to the fuel pump and sensor: The fuel pump assembly and level sensor are typically located within the tank.
3. Disconnect the Fuel Lines: This is crucial and potentially messy. You'll need to carefully disconnect the fuel lines. Have a container ready to catch any spilled fuel. Consider using fuel line clamps to prevent leaks. Properly depressurize the fuel system is also a crucial safety step; consult your repair manual for the appropriate procedure.
4. Disconnect Electrical Connectors: Unplug the electrical connector from the fuel level sensor. Take pictures or make notes of the connector placement before disconnecting to assist with reinstallation.
5. Remove the Fuel Level Sensor: This usually involves removing bolts or nuts securing the sensor to the fuel pump assembly or the tank itself. Again, refer to your repair manual for the exact procedure.
6. Install the New Fuel Level Sensor: Carefully install the new fuel level sensor, ensuring it's seated correctly.
7. Reconnect Everything: Carefully reconnect the electrical connector, fuel lines, and tank straps. Tighten all bolts and nuts to the specifications in your repair manual.
8. Raise the Fuel Tank: Carefully raise the fuel tank back into its position.
9. Reconnect the Battery: Once everything is secure, reconnect the negative battery terminal.
10. Check for Leaks: Inspect all connections for leaks. Start the truck and check the fuel gauge to verify the new sensor is working correctly.
Important Considerations:
* Repair Manual: A repair manual specific to your 1999 Silverado is highly recommended. It will provide detailed diagrams, torque specifications, and other vital information to make the job much safer and easier.
* Fuel Pump: Often, the fuel pump and level sensor are one assembly. Replacing only the sensor may not be possible; you might need to replace the entire assembly.
* Professional Help: If you are not comfortable working with fuel systems or you lack the necessary tools, consider having a qualified mechanic perform the repair. This is a job that, if done incorrectly, can lead to significant safety hazards and damage.
This is a general overview; the specific steps might vary slightly. Always refer to your vehicle's repair manual for precise instructions. Remember safety is paramount when working with fuel systems.
