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Home >> Chevrolet >> 2009 >> Impala SS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 5.3L - Introduction >> Repair Instructions >> Fuel Tank Fuel Pump Module Replacement >> Removal Procedure
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Removal Procedure

    Fig 1: View Of Fuel Sender Module Electrical Connectors
    GM1404633Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
  2. Disconnect the fuel sender module electrical connectors.
    3. Fig 2: Identifying Fuel Pipes At Fuel Sender
    GM1404528Courtesy of GENERAL MOTORS CORP.
    CAUTION: 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.
  3. Disconnect the fuel pipes from the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
    4. Fig 3: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    CAUTION: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
    CAUTION: 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.
    NOTE: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
  4. Use the J 45722  and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.
    5. Fig 4: Identifying Fuel Sender Lock Ring
    GM1404533Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel sender lock ring (1) and the fuel sender (2) from the fuel tank.
  6. Remove and discard the fuel sender seal (3).
  7. Remove the fuel level sensor from the fuel sender module. Refer to Fuel Level Sensor Replacement .
    8. Fig 5: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.
    • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
    • Check the lock ring for flatness.
  8. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
  9. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  10. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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