GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Caprice 🢒 Engine 🢒 Engine Controls - 4.3L (Caprice Only) and 5.7L 🢒 Fuel Sender Assembly Replacement

Removal Procedure

    Object Number: 21301 Size: SH

    Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

    Notice: 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.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
  3. Drain the fuel tank. Refer to Draining Fuel Tank.
  4. Remove the fuel tank. Refer to Fuel Tank and Fuel Filler Pipe Replacement.
  5. Remove the fuel sender assembly retaining nuts (1), the retaining ring (2), the fuel sender assembly (3), and the gasket (4). Discard the gasket.
  6. Clean the gasket sealing surfaces.

Installation Procedure

    Object Number: 21301 Size: SH
  1. Position the new gasket (4) on the fuel tank (5).

    2. Important: Do Not 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 the float arm.

  2. Install the fuel sender assembly (3), the retaining ring (2), and the fuel sender retaining nuts (1).

    3. Tighten
    Tighten the fuel sender assembly retaining nuts alternately and evenly to 3 N·m (27 lb in).

  3. Install the fuel tank. Refer to Fuel Tank and Fuel Filler Pipe Replacement.
  4. Add fuel.
  5. Install the fuel filler cap.
  6. Connect the negative battery cable.
  7. Inspect for leaks.
    8. 7.1. Turn the ignition switch ON for 2 seconds.
    7.2. Turn the ignition switch OFF for 10 seconds.
    7.3. Turn the ignition switch ON.
    7.4. Check for fuel leaks.