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Home >> Chevrolet >> 2004 >> Impala LS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System 3.8L (Introduction) >> Repair Instructions >> Fuel Sender Assembly Replacement >> Removal Procedure
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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
IMPORTANT: For rear compartment (trunk) accessible fuel sender assemblies, completely remove the rear compartment carpet before removing the fuel sender access panel.
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 when servicing fuel system components.
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the rear compartment trim panel. Refer to Compartment Trim Panel Replacement - Rear in Body Rear End.
  3. Remove the fuel sender access panel nuts.
  4. Remove the fuel sender access panel.
    5. Fig 1: Removing Fuel Sender Access Panel
    GM65739Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the fuel tank pressure sensor electrical connector.
  6. Disconnect the fuel sender electrical connector.
  7. Clean the fuel pipes, and fuel sender assembly to prevent possible fuel contamination during removal.
  8. Disconnect the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  9. Remove the fuel sender retaining ring.
  10. Remove the modular fuel sender assembly.
  11. Clean the fuel sender assembly O-ring sealing surfaces.
  12. Inspect the fuel sender assembly O-ring sealing surfaces.
    13. Fig 2: Removing Fuel Sender O-Ring
    GM66012Courtesy of GENERAL MOTORS CORP.
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