Replacing The Fuel Sending Unit In Your 2003 Buick Regal

The fuel level sending unit in a 2003 Buick Regal is located in the fuel tank and sends a constant signal indicating the amount of fuel that remains. When the unit fails, the fuel gauge will not operate, and the check engine light may come on. The fuel level sending unit can be replaced, and there are several online guides and videos that explain how to do this. The cost of a new fuel level sending unit ranges from $50 to over $1000.

Removing the fuel sending unit

• Scrape the pads off the old fuel tank.
• Put the pads onto the same spot on the new fuel tank.
• Twist the fuel lines off the fuel sending unit.
• Remove the fuel tank ring from the tank with a hammer and chisel. Twist the ring off the tank.
• Pull the fuel sending unit out of the tank.
• Pull the fuel pump off the sending unit.

Note: This is part 2 of a three-part video. Please consult Part 1 for prior instructions.

Preparing the fuel sending unit

Now that you have removed the fuel sending unit from the fuel tank, you can begin preparing the new one for installation. Here are the steps you need to follow:

• Put the fuel pump hose clamp onto the new fuel sending unit. This will ensure a secure connection between the fuel pump and the sending unit.
• Place the insulator onto the sending unit. The insulator helps to prevent vibrations and reduce wear and tear on the components.
• Install the filter onto the sending unit. The filter will help to keep the fuel clean and free of contaminants.
• Push the pump onto the sending unit. Make sure it is securely attached. The pump will draw fuel from the tank and send it to the engine.
• Put the insulator onto the fuel pump. This will help to reduce vibrations and prevent damage to the pump.

At this point, your new fuel sending unit is prepared and ready for installation back into the fuel tank. Make sure to follow the remaining steps carefully to ensure a successful and safe repair.

Installing the fuel sending unit

Now that you've removed the old fuel sending unit and prepared the new one, it's time to install the new unit. Here's a step-by-step guide:

• Put the gasket into the fuel tank. This will ensure a tight seal and prevent any fuel leaks.
• Place the fuel tank ring onto the new sending unit. Make sure it's properly aligned and secured.
• Carefully lower the new sending unit into the fuel tank. Ensure it's positioned correctly and securely in place.
• Position the fuel tank ring so that it sits flush with the fuel tank. Use a hammer and chisel to gently tap the ring tabs until the ring is securely in place.
• Attach the hoses to the sending unit. Ensure they are securely connected to the appropriate fittings.
• Consult the vehicle-specific repair manual or a trusted mechanic if you encounter any issues or need further guidance.

Post-Installation Checks:

Once you've installed the new fuel sending unit, there are a few checks you should perform to ensure everything is functioning correctly:

• Turn on the ignition but do not start the engine. Check for any fuel leaks around the sending unit and hose connections.
• Inspect the fuel gauge in the dashboard to ensure it is functioning correctly and accurately reflecting the fuel level.
• Start the engine and let it run for a few minutes. Observe for any unusual noises or behaviour.
• Take the vehicle for a test drive and pay attention to how the vehicle performs, including acceleration, fuel consumption, and any unusual smells or sounds.
• If everything seems to be functioning correctly, your new fuel sending unit has been successfully installed!

Disconnecting the fuel lines

Once the fuel lines are disconnected, you can remove the lock ring that holds the fuel sending unit in place. Use an impact tool to do this, turning it around the ring until you feel some resistance, at which point the ring should come off. Now, carefully remove the whole assembly from the fuel tank.

Replacing the fuel pump

Step 1: Beginning the Repair

This is Part 2 of a three-part video. Please consult Part 1 for prior instructions. Perform the steps outlined in Part 1.

Step 2: Removing the Fuel Sending Unit

Scrape the pads off the old fuel tank. Put the pads onto the same spot on the new fuel tank. Twist the fuel lines off the fuel sending unit. Remove the fuel tank ring from the tank with a hammer and chisel. Twist the ring off the tank. Pull the fuel sending unit out of the tank. Pull the fuel pump off the sending unit.

Step 3: Preparing the Fuel Sending Unit

Put the fuel pump hose clamp onto the fuel sending unit. Put the insulator onto the sending unit. Put the filter onto the sending unit. Push the pump onto the sending unit. Put the insulator onto the fuel pump.

Step 4: Installing the Fuel Sending Unit

Put the gasket into the fuel tank. Put the fuel tank ring onto the sending unit. Lower the sending unit into the tank. Position the fuel tank ring. Hammer on the ring tabs with a hammer and chisel. Push the hoses onto the sending unit.

Step 5: Continuing the Repair

This is Part 2 of a three-part video. Please consult Part 3 for further instructions. Perform the steps outlined in Part 3.

Parts

You can find the fuel pump module assembly for your 2003 Buick Regal at AutoZone, Dorman, or USMW Professional Series.

Frequently asked questions