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Home >> Chevrolet >> 2005 >> Chevy Express G3500, Van Passenger Extended >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 4.8L, 5.3L, And 6.0L - Introduction >> Repair Instructions >> Fuel Sender Assembly Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Fuel Sender
    GM331709Courtesy of GENERAL MOTORS CORP.
    CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.
  1. Install the new seal on the fuel tank.
    2. IMPORTANT: The fuel strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel strainer does not block full travel of the float arm.
  2. Install the fuel sender assembly into the fuel tank.
  3. Install the retaining ring to the fuel sender assembly using the J 39765 
  4. Install the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Side Tank)  or Fuel Tank Replacement (Passenger/Cargo Van)  or Fuel Tank Replacement (Cutaway Van Rear Tank) .
  5. Refill the fuel tank.
  6. Tighten the fuel filler cap.
  7. Connect the negative battery cable.
  8. Inspect for leaks:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
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