GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Impala 🢒 Vehicle Control Systems 🢒 Vehicle DTC Information 🢒 Fuel Sender Assembly Replacement

Removal Procedure

    Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:

       • Use forced air ventilation such as a fan set outside of the trunk.
       • Plug or cap any fuel system openings in order to reduce fuel vapor formation.
       • Clean up any spilled fuel immediately.
       • Avoid sparks and any source of ignition.
       • Use signs to alert others in the work area that fuel system work is in process.

    Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:

       • The fuel pipe connections
       • The hose connections
       • The areas surrounding the connections

    Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

    Important: Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.

    Important: The modular fuel sender assembly will spring-up when the snap ring is removed.

    Important: Always maintain cleanliness while servicing fuel system components.

  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    4. Object Number: 186674 Size: SH
  4. Loosen the fuel filler hose clamp (1) at the fuel tank (3).

    5. Object Number: 155468 Size: SH
  5. Remove the fuel tank filler hose from the fuel tank.

    6. Object Number: 32401 Size: SH
  6. Disconnect the fuel feed, and the fuel return pipes at the fuel filter area. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the evaporative emission (EVAP) pipe from the connection at the front of the fuel tank.
  8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.

    9. Object Number: 698635 Size: SH
  9. Separate the EVAP fresh air hose at the splice.

    10. Object Number: 699555 Size: SH
  10. Remove the fuel tank shield push pins (2).
  11. Remove the fuel tank shield (3).
  12. Install a transmission jack to the fuel tank (1).

    13. Notice: Refer to Damage to Fuel Tank Straps Notice in the Preface section.


    Object Number: 699556 Size: SH
  13. Remove the fuel tank strap bolts (2) from the fuel tank straps.
  14. Remove the fuel tank (1) from the vehicle .
  15. Place the fuel tank in a suitable work area.

    16. Object Number: 65739 Size: SH
  16. Disconnect the fuel tank pressure sensor electrical connector.
  17. Disconnect the fuel sender electrical connector.
  18. Clean the fuel pipes, the fuel sender assembly to prevent possible fuel contamination during removal.
  19. Disconnect the quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .

    20. Object Number: 66012 Size: SH
  20. Remove the fuel sender retaining ring.
  21. Remove the modular fuel sender assembly.
  22. Clean the fuel sender assembly O-ring sealing surfaces.
  23. Inspect the fuel sender assembly O-ring sealing surfaces.

Installation Procedure

    Notice: Refer to Fuel System Ground Notice in the Preface section.

    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: Ensure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.


    Object Number: 66012 Size: SH
  1. Position the new fuel sender assembly O-ring on to the fuel tank.
  2. Install the fuel sender assembly into the fuel tank.
  3. Install the fuel sender assembly retaining ring while holding the fuel sender assembly down.
  4. Connect the fuel sender electrical connector.
  5. Connect the fuel tank pressure sensor electrical connector.
  6. Connect the quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Install the fuel tank to a transmission jack.

    8. Object Number: 699556 Size: SH
  8. Raise the fuel tank (1) to the original position.

    9. Notice: Refer to Fastener Notice in the Preface section.

  9. Install the fuel tank strap bolts (2).

    10. Tighten
    Tighten the bolts to 47 N·m (35 lb ft).

  10. Remove the transmission jack.

    11. Object Number: 699555 Size: SH
  11. Install the fuel tank shield (3).
  12. Install the fuel tank shield push pins (2).

    13. Object Number: 32401 Size: SH
  13. Connect the quick-connect fittings at the fuel filter area. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the EVAP pipe at the front of the fuel tank.

    15. Object Number: 698635 Size: SH
  15. Connect the EVAP fresh air hose at the splice.

    16. Object Number: 155468 Size: SH
  16. Install the fuel tank filler hose to the fuel tank.

    17. Object Number: 186674 Size: SH
  17. Fully seat the filler hose (4) on the fuel tank port (2).
  18. Ensure the clamp (1) is properly located on the tank port between the bead (5) and the tank (3).

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

  19. Install the exhaust pipe hangers.
  20. Lower the vehicle.
  21. Add fuel and install the fuel filler pipe cap.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  23. Inspect for fuel leaks using the following procedure:
    24. 23.1. Turn ON the ignition, for 2 seconds.
    23.2. Turn OFF the ignition, for 10 seconds.
    23.3. Turn ON the ignition.
    23.4. Inspect for fuel leaks.