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Home >> Chevrolet >> 2005 >> Impala Base, 3.4 E >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 3.4L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Sender Assembly Replacement >> Removal Procedure

Removal Procedure

    CAUTION: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:
    • Use forced air ventilation such as a fan set outside of the trunk.
    • Plug or cap any fuel system openings in order to reduce fuel vapor formation.
    • Clean up any spilled fuel immediately.
    • Avoid sparks and any source of ignition.
    • Use signs to alert others in the work area that fuel system work is in process.
    NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
    • The fuel pipe connections
    • The hose connections
    • The areas surrounding the connections
    NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure  Fuel Pressure Relief Procedure.
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    4. Fig 1: Identifying Fuel Tank Components
    GM186674Courtesy of GENERAL MOTORS CORP.
  4. Loosen the fuel filler hose clamp (1) at the fuel tank (3).
    5. Fig 2: View Of Fuel Tank Filler Hose
    GM155468Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel tank filler hose from the fuel tank.
    6. Fig 3: View Of Fuel Feed & Return Pipes
    GM32401Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel feed, the fuel return and the evaporative emission (EVAP) pipes quick-fittings at the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Remove the exhaust pipe hangers in order to allow the exhaust system to drop slightly.
    8. Fig 4: View Of EVAP Fresh Air Hose
    GM698635Courtesy of GENERAL MOTORS CORP.
  8. Separate the 2 halves of the EVAP fresh air line at the splice.
    9. Fig 5: View Of Fuel Tank Shield
    GM699555Courtesy of GENERAL MOTORS CORP.
  9. Remove the fuel tank shield push pins (2) and the fuel tank shield (3).
    10. Fig 6: View Of Fuel Tank
    GM699556Courtesy of GENERAL MOTORS CORP.
  10. Support the fuel tank with a suitable jack.
    11. NOTE: Refer to Damage to Fuel Tank Straps Notice in Cautions and Notices.
  11. Remove the fuel tank strap bolts (2).
  12. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
  13. Disconnect the fuel tank pressure sensor electrical connector.
  14. Disconnect the fuel sender electrical connector.
  15. Clean the fuel pipes, the fuel sender assembly to prevent possible fuel contamination during removal.
  16. Disconnect the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    17. Fig 7: View Of Fuel Sender Retaining Ring
    GM66012Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The modular fuel sender assembly will spring-up when the snap ring is removed.
  17. Remove the fuel sender retaining ring.
  18. Remove the modular fuel sender assembly.
  19. Clean the fuel sender assembly sealing surfaces.
  20. Inspect the fuel sender assembly sealing surfaces.
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