GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Chevy Suburban - 4WD 🢒 Engine 🢒 Engine Controls - 6.5L 🢒 Fuel Sender Assembly Replacement

Removal Procedure
  1. Remove fuel tank filler cap.
  2. Disconnect the negative battery cable(s). Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  3. Raise the vehicle on a hoist.

    4. Notice: Use extreme care when lowering the fuel tank. The fuel sender is made of plastic. Lowering the fuel tank may damage the fuel sender.

  4. Remove the fuel tank.

    5. Object Number: 17406 Size: SH
  5. Remove the sender unit by turning the cam lock counterclockwise using tool J36608 .

    6. Object Number: 28226 Size: SH

    Important: Do not damage the rubber insulator or the strainer.

  6. Remove the sending unit by pulling up.
  7. Inspect the attaching hose for signs of deterioration.
  8. Inspect the rubber sound insulation at the bottom of the pump.
  9. Inspect the strainer.

Installation Procedure
  1. Install the sender assembly into the attaching hose.

    2. Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

  2. Install the sending unit assembly into the fuel tank.

    3. Object Number: 28226 Size: SH
  3. Insert a new O-ring seal.

    4. Object Number: 17406 Size: SH
  4. Install the cam lock assembly.
  5. Turn the cam lock clockwise in order to lock it.
  6. Install the fuel tank.
  7. Connect the negative battery cable.
  8. Check the system for leaks.