GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Epica 🢒 Engine 🢒 Engine Controls - 2.5L (LBK) 🢒 Fuel Sender Assembly Replacement

Removal Procedure

    Notice: Refer to Fuel Pressure Notice in the Preface section.


    Object Number: 1256138 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the negative battery cable.
  3. Remove the rear seat. Refer to Rear Split Folding Seat Back Replacement
  4. Remove the fuel sender assembly access cover.

    5. Object Number: 1256139 Size: SH
  5. Disconnect the electrical connector at the fuel pump assembly.
  6. Disconnect the fuel outlet line.
  7. Disconnect the fuel tank return line.
  8. Turn the lock ring counterclockwise to clear the tank tabs.
  9. Remove the fuel sender assembly from the tank.

Installation Procedure


    Object Number: 1256140 Size: SH
  1. Clean the gasket mating surface on the fuel tank.
  2. Position the new gasket in place.
  3. Install the fuel sender assembly into the fuel tank in the same location as removed for ease of line and connector installation.
  4. Position the lock ring in place and turn it clockwise until it contacts the tank stop.
  5. Connect the fuel pump assembly connector.
  6. Install the fuel sender assembly outlet line.
  7. Install the fuel tank return line.
  8. Install the fuel sender assembly access cover.
  9. Connect the negative battery cable.
  10. Perform an operational check of the fuel pump.
  11. Install the rear seat. Refer to Rear Split Folding Seat Back Replacement