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Home >> Chevrolet >> 2005 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - (Introduction) Specifications & Repair Instructions >> Repair Instructions >> Fuel Sender Assembly Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Identifying Fuel Sender Assembly
    GM587722Courtesy of GENERAL MOTORS CORP.
    CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.
  1. Install the new seal on the fuel tank.
    2. IMPORTANT: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.
  2. Install the fuel sender assembly into the fuel tank.
  3. Install the fuel sender assembly retaining ring using the J 39765  . See Special Tools .
  4. Connect the fuel and EVAP pipes to the fuel sender.
  5. Connect the fuel sender electrical connectors.
  6. Install the fuel tank. Refer to Fuel Tank Replacement .
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