I don't know if anyone is as unlucky when it comes to fuel level sensors going bad on the numerous gm vehicles my family and I have owned lol. I've decided to have mine fixed because I'm getting sick of my gauge going from full to completely empty telling me I have low fuel and having to rely on the tripometer. I went to a shop to get an idea of what it would cost to replace to the fuel level sensor on the pump. They tell me that I cant just replace the fuel level sensor, instead they have to replace to the whole fuel pump..... uhhh sure about that? Why would they sell the ac delco fuel level sensor separate then? They gave me a total price of $710, $500 for a bosch fuel pump and $210 for labor. Can anyone confirm that the sensor can be replaced separately? Would it be worth it to replace the fuel pump at 140,000 miles being probably 2/3's through its life? I could get the parts from rock auto or amazon for a lot cheaper and possibly tackle this project on my own if its not too dangerous. The ac delco and bosch fuel pump go for around $240 at amazon or just the ACDelco SK1051 Fuel Level Sensor goes for $72.55.

Sounds like that shop is trying to rip you off. I'm almost 100% certain that the fuel level sensor is separate from the pump itself. But seeing that you've got 140k on the pump, it wouldn't be bad insurance to go ahead and replace the fuel pump while you're at it. If you're tight on money, I'd say "If it ain't broke.. why fix it?"
I believe on the GP's, you'd have to drop the fuel tank to get access to the pump and the level sensor anyways, so may as well change both of them out while the tank is out, right? I'd run the tank pretty low before attempting on dropping the tank. That'd save you a lot of headaches.

As for the fuel level sensor.. not exactly sure where that's located on a GP, but I wouldn't doubt if it were internally mounted inside the tank somewhere.

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I believe the 04's have an access panel in the trunk (see pic) to get to the fuel pump/level sender so the tank doesn't have to be dropped unlike the later years (what a piss poor idea especially since later years had the fuel filter in the tank and not externally like the 97-04's). As for the level sender itself, yes I do believe that you can replace that as a separate part so the pump does not have to be replaced, but they are connected as one whole assembly if I recall correctly, so that's probably why the mechanic is saying replace both, since they he can just take the pump/sender assembly out and throw a new one in and not have to deal with taking the sender off the old fuel pump and installing a new sender on it.

If you want to attempt it yourself or just want some more info on what's going on with it, look at this writeup.
http://redhouseon7th.com/redhouse/howto ... index.html
And you can refer to the Service manual at the top of the page and search Document ID: 925322 for how to replace the Level Sender.

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Dubs:00 VW GTI VR6, Low and Slow 91 VW GTI 8v, Shave the Bay!! 91 VW Cabriolet 8v, bitch Basket
GP's:04 GP GT, Past now G-Ma's Girlfriend's 97 GP GT, "Project Pink Power"

If your buying from the auto parts store they only sell the fuel pump as an assembly. The cheapest place i found them was on ebay. And yes there is a access panel in the trunk so you dont have to drop the tank. Unfortunately for some the did away with that feature in the 05+ GPs.

Sent from my DROID BIONIC using Tapatalk

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After giving this a long thought I decided I should just have the fuel pump replaced altogether as the fuel pump is probably nearing the end of its life. Thanks for the link - http://redhouseon7th.com/redhouse/howto ... index.html
From the writeup, the person had a hard getting to fuel level sensor to fit and work just to have the fuel pump go a few months later!

... Why is a sending unit so hard to get wherever you guys are?? A number of our auto suppliers carry them. I could get a part number tomorrow if you'd like...

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Fast.Loud.Shiny

Mine took a crap as well recently, still have yet to replace it. I would stay with a gm part for this type of repair. I have seen and heard aftermarket sensors not reading correctly.

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