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Home >> Chevrolet >> 2004 >> Impala SS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System 3.8L (Introduction) >> Repair Instructions >> Fuel Sender Assembly Replacement >> Installation Procedure
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Installation Procedure

    NOTE: Refer to Fuel System Ground Notice in Cautions and Notices.
    IMPORTANT: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.
    IMPORTANT: Ensure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.
  1. Position the new fuel sender assembly O-ring on the fuel tank.
    2. Fig 1: Installing Fuel Sender O-Ring
    GM66012Courtesy of GENERAL MOTORS CORP.
  2. Install the fuel sender assembly into the fuel tank.
  3. Install the fuel sender assembly retaining ring while holding the fuel sender assembly down.
  4. Connect the fuel sender electrical connector.
  5. Connect the fuel tank pressure sensor electrical connector.
  6. Connect the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Install the fuel filler cap.
  8. Connect the negative battery cable. Refer toBattery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  9. Inspect for leaks.
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
  10. Install the fuel sender access panel.
    11. NOTE: Refer to Fastener Notice in Cautions and Notices.
  11. Install the fuel sender access panel nuts.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    12. Fig 2: Installing Fuel Sender Access Panel
    GM65739Courtesy of GENERAL MOTORS CORP.
  12. Install the rear compartment trim panel. Refer to Compartment Trim Panel Replacement - Rear in Body Rear End.
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