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Home >> Chevrolet >> 2006 >> Avalanche 2500 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 8.1L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Sender Assembly Replacement (Front Tank) >> Removal Procedure

Removal Procedure

    Fig 1: View Of Fuel & EVAP Lines At Fuel Tank Module (Front Tank)
    GM1372816Courtesy of GENERAL MOTORS CORP.
  1. Remove the front fuel tank. Refer to Fuel Tank Replacement (Front Tank)  or Fuel Tank Replacement (Rear Tank) .
  2. Disconnect the fuel and evaporative emission (EVAP) lines from the fuel tank module. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    3. Fig 2: Using J 45722 To Remove/Install The Sending Unit Lock Ring
    GM1372817Courtesy 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.
  3. Use the J 45722  and a long breaker-bar in order to unlock the fuel sender lock ring.
  4. Remove J 45722  and the lock ring.
    5. Fig 3: View Of Vapor Line Quick Connect Fitting (Front Tank)
    GM1372818Courtesy of GENERAL MOTORS CORP.
  5. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fitting below the module cover.
  6. Disconnect the vapor line quick connect fitting (1) in order to remove the module. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Remove the module from the fuel tank.
  8. Remove and discard the fuel tank module seal.
    9. Fig 4: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Some lock rings 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.
  9. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
  10. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  11. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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