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Home >> Chevrolet >> 2011 >> Chevy Express G1500, Van Cargo, 4.3 X >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 4.3L - Repair Instructions >> Repair Instructions >> Fuel Tank Fuel Pump Module Replacement >> Removal Procedure
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Removal Procedure

    Fig 1: Fuel Tank Fuel Feed Pipe Quick Connect Fittings
    GM1940956Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement (E26) , Fuel Tank Replacement (Without E26) .
  2. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
  3. Disconnect the evaporative emission (EVAP) pipe quick connect fitting (2) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Disconnect the EVAP front pipe quick connect fitting (3) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Reposition the fuel and EVAP pipe ends out of the way.
    6. Fig 2: Fuel Tank Module Lock Ring
    GM1940960Courtesy of GENERAL MOTORS CORP.
  6. Install the J 45722  fuel sender lock nut wrench (1) to the fuel tank module lock ring.
    7. Fig 3: Rotating Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    CAUTION:

    Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

    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.

  7. Using the J 45722  fuel sender lock nut wrench, and a long breaker-bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring.
    8. Fig 4: Fuel Tank Module
    GM1940986Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel tank module lock ring (1).
    9. 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.

  9. Slowly raise the module (2) until the fuel level sensor float arm is just visible.
    10. NOTE:

    When removing the module from the fuel tank, be aware that the module bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

  10. Tilt the module towards the left of the fuel tank to allow the level sensor to clear the tank opening. Remove the module from the tank.
  11. Carefully discard the fuel in the module reservoir bucket into an approved container.
    12. NOTE:

    DO NOT reuse the old fuel tank module O-ring seal.

  12. Remove and discard the fuel tank module O-ring seal (3).
    13. Fig 5: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Some lock rings 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.
  13. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
  14. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  15. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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