Fuel Sender Assembly Service

REMOVAL PROCEDURE

WARNING: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container; due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Relieve the fuel system fuel pressure.
2. Drain the fuel tank.
3. Remove the fuel sender assembly.

DISASSEMBLE PROCEDURE
1. Inspect the position of the fuel strainer for installation.
2. Support the reservoir with one hand and grasp the fuel strainer with the other hand.
3. Place the fuel sender assembly upside down on a bench.
4. Remove the fuel sender strainer.
5. Inspect the fuel sender strainer. If the fuel sender strainer is contaminated, the fuel tank should be cleaned. Discard the fuel level sensor after inspection.
6. Remove the electrical connectors from the fuel pump and cover assembly.
7. Remove the fuel level sensor assembly.

ASSEMBLE PROCEDURE

IMPORTANT: Always install a new fuel level strainer when installing a fuel sender or fuel level sensor assembly.

1. Position the new fuel sender strainer on the fuel sender and push the outer edge of the fuel sender strainer until the fuel sender strainer is fully seated.
2. Install the new fuel level sensor assembly.
3. Install the electrical connectors to the fuel pump and the cover assembly.

INSTALLATION PROCEDURE

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application.

General Motors will call out those fasteners that require a replacement after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant.

UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications.

Following these instructions can help you avoid damage to parts and systems.
1. Install the fuel sender assembly. Refer to Fuel Sender Assembly
2. Add fuel and install the fuel tank filler pipe cap.
3. Install the negative battery cable.
4. Inspect for leaks.
- Turn the ignition switch to the On position for 2 seconds.
- Turn the ignition switch to the Off for 10 seconds.
- Turn the ignition switch to the On position.
- Check for fuel leaks.


LEGEND IMAGE (2)
1. Fuel Sender Assembly
2. Fuel Level Sensor Assembly
3. Filter
4. Fuel Pump