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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 >> Removal Procedure
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Removal Procedure

  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
    2. Fig 1: Identifying Fuel Sender Assembly
    GM587722Courtesy of GENERAL MOTORS CORP.
    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.
  2. Disconnect the fuel sender electrical connectors.
  3. Disconnect the fuel and EVAP pipes from the fuel sender.
  4. Remove the fuel sender assembly retaining ring using the J 39765  . See Special Tools .
    5. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
  5. Remove the fuel sender assembly and the seal. Discard the seal.
  6. Clean the fuel sender sealing surfaces.
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