GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Conventional) C6/C7/C8 🢒 Engine 🢒 Engine Controls - 7.2L (Caterpillar) 🢒 Fuel Sender Assembly Replacement

Removal Procedure
  1. Remove the fuel tank. Refer to Fuel Tank Replacement .

    2. Object Number: 1170857 Size: SH
  2. Remove the 6 nuts and washers from the fuel sender assembly retaining ring .
  3. Remove the fuel sender assembly retaining ring.
  4. Remove the fuel sender assembly.

    5. 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.

  5. Remove the fuel sender assembly seal from the fuel tank.

Installation Procedure
  1. Install the fuel sender assembly seal to the fuel tank.

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

  2. Care should be taken not to fold over or twist the strainer when installing the sender assembly as this will restrict fuel flow.

    3. Object Number: 1170857 Size: SH
  3. Install the fuel sender assembly in the fuel tank.
  4. Install the fuel sender assembly lock ring to the fuel tank. Ensure the lock ring alignment holes fit over the tabs on the tank.

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

  5. Install the 6 washers and nuts retaining the fuel sender assembly lock ring.

    6. Tighten
    Tighten the lock ring nuts to 11 N·m (97 lb in).

  6. Install the fuel tank. Refer to Fuel Tank Replacement .