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Home >> Chevrolet >> 2005 >> Impala LS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 3.8L (L36 And L67) - 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.
    IMPORTANT: Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.
    IMPORTANT: The modular fuel sender assembly will spring-up when the snap ring is removed.
    IMPORTANT: Always maintain cleanliness while servicing fuel system components.
  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 and support 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, and the fuel return pipes at the fuel filter area. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Disconnect the evaporative emission (EVAP) pipe from the connection at the front of the fuel tank.
  8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
    9. Fig 4: View Of EVAP Fresh Air Hose
    GM698635Courtesy of GENERAL MOTORS CORP.
  9. Separate the EVAP fresh air hose at the splice.
    10. Fig 5: View Of Fuel Tank Shield
    GM699555Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel tank shield push pins (2).
  11. Remove the fuel tank shield (3).
  12. Install a transmission jack to the fuel tank (1).
    13. Fig 6: View Of Fuel Tank
    GM699556Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Damage to Fuel Tank Straps Notice in Cautions and Notices.
  13. Remove the fuel tank strap bolts (2) from the fuel tank straps.
  14. Remove the fuel tank (1) from the vehicle.
  15. Place the fuel tank in a suitable work area.
    16. Fig 7: Locating Fuel Sender Access Panel
    GM65739Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the fuel tank pressure sensor electrical connector.
  17. Disconnect the fuel sender electrical connector.
  18. Clean the fuel pipes, the fuel sender assembly to prevent possible fuel contamination during removal.
  19. Disconnect the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    20. Fig 8: View Of Fuel Sender Retaining Ring
    GM66012Courtesy of GENERAL MOTORS CORP.
  20. Remove the fuel sender retaining ring.
  21. Remove the modular fuel sender assembly.
  22. Clean the fuel sender assembly O-ring sealing surfaces.
  23. Inspect the fuel sender assembly O-ring sealing surfaces.
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