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Home >> Chevrolet >> 2004 >> Monte Carlo LS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System 3.4L (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: Be sure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.
    IMPORTANT: Always replace the fuel sender seal when reinstalling the fuel sender assembly.
  1. Position the new fuel sender assembly seal on the fuel tank.
  2. Place the fuel sender assembly into the fuel tank.
  3. While holding the fuel sender in place install the fuel sender assembly retaining snap ring.
    4. Fig 1: Installing Fuel Sender Retaining Ring
    GM66012Courtesy of GENERAL MOTORS CORP.
  4. Connect the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  5. Connect the fuel sender electrical connector.
  6. Connect the fuel tank pressure sensor electrical connector.
  7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  8. Inspect the fuel system for leaks by performing the following steps:
    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.
  9. Install the fuel sender access panel.
    10. NOTE: Refer to Fastener Notice in Caution and Notices.
  10. Install the fuel sender access panel nuts.

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

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