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Home >> Chevrolet >> 2006 >> Uplander Base >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 3.5L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Sender Assembly Replacement (Short Wheel Base) >> Removal Procedure

Removal Procedure

    Fig 1: Identifying Fuel Sender Assembly (Short Wheel Base)
    GM1544792Courtesy of GENERAL MOTORS CORP.
    NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement (Long Wheel Base)  or Fuel Tank Replacement (Short Wheel Base) .
  2. Disconnect the fuel sender electrical connections (4).
  3. Clean all of the fuel pipe connections, all of the hose connections and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
  4. Disconnect the fuel supply pipe quick-connect fitting (3) at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  5. Disconnect the evaporative emission (EVAP) pipe quick-connect fittings (5, 6) at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    6. Fig 2: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
    NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
    IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
  6. Use the J 45722  and a long breaker-bar in order to unlock the fuel sender lock ring. See Special Tools . Turn the fuel sender lock ring in a counterclockwise direction.
    7. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
  7. Remove the fuel sender assembly (7) and the seal (2) from the fuel tank.
  8. Discard the fuel sender assembly seal.
  9. Clean the fuel sender assembly sealing surfaces.
    10. Fig 3: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.
    IMPORTANT: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
    IMPORTANT: Check the lock ring for flatness.
  10. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
  11. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  12. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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