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Home >> Chevrolet >> 2005 >> Impala Base, 3.4 E >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 3.4L - Introduction (2 Of 2) >> 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.
    Fig 1: View Of Fuel Sender Retaining Ring
    GM66012Courtesy of GENERAL MOTORS CORP.
  1. Position the new fuel sender assembly seal into 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. 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. NOTE: Refer to Nylon Pipes Notice in Cautions and Notices.
    Fig 2: View Of Fuel Tank
    GM699556Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel tank to a suitable jack.
  8. Raise the fuel tank to the original position.
    9. NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 48 N.m (35 lb ft).

    10. Fig 3: View Of Fuel Tank Shield
    GM699555Courtesy of GENERAL MOTORS CORP.
  10. Position the tank shield (3), and install the push pins (2).
    11. Fig 4: View Of Fuel Feed & Return Pipes
    GM32401Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel feed, the fuel return and the EVAP pipes quick-connect fittings at the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    12. Fig 5: View Of EVAP Fresh Air Hose
    GM698635Courtesy of GENERAL MOTORS CORP.
  12. Install the 2 halves of the EVAP fresh air hose at the splice.
    13. Fig 6: View Of Fuel Tank Filler Hose
    GM155468Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel tank filler hose to the fuel tank.
    14. Fig 7: Identifying Fuel Tank Components
    GM186674Courtesy of GENERAL MOTORS CORP.
  14. Fully seat the filler hose (4) on the fuel tank port (2).
  15. Ensure the clamp (1) is properly located on the tank port between the bead (5) and the tank (5).

    Tighten:  Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).

  16. Raise the exhaust to the original and install the exhaust pipe hangers.
  17. Lower the vehicle.
  18. Add fuel and install the fuel filler pipe cap.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  20. Inspect for fuel leaks using the following procedure:
    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.
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