GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2003 🢒 Sonoma Pickup - 2WD 🢒 Body and Accessories 🢒 Body Rear End 🢒 Fuel Sender Assembly Replacement

Removal Procedure

    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.

    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.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Remove the pickup box. Refer to Pickup Box Replacement in Body Rear End.
  4. Disconnect the fuel sender electrical connectors.
  5. Disconnect the fuel sender fuel and evaporative emission (EVAP) pipes.

    6. Object Number: 54674 Size: SH

    Important: 

       • The modular fuel sender assembly may spring up from the fuel tank.
       • When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The fuel sender assembly must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one.
       • Carefully discard the reservoir fuel into an approved container.

  6. While holding the modular fuel sender assembly down, remove the snap ring from designated slots (1) located on the retainer.

Installation Procedure

    Object Number: 54674 Size: SH
  1. Install a new O-ring on the modular fuel sender to the tank.
  2. Align the tab on front of the modular sender with slot on front of the retainer snap ring.
  3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.

    4. Important: Ensure that the snap ring is fully seated within the tab slots.

  4. Insert snap ring into designated slots (1).
  5. Connect the fuel sender fuel and EVAP pipes.
  6. Connect the fuel sender electrical connectors.
  7. Connect the negative battery cable.
  8. Inspect for fuel leaks through the following steps:
    9. 8.1. Turn ON the ignition for 2 seconds.
    8.2. Turn OFF the ignition for 10 seconds.
    8.3. Turn ON the ignition.
    8.4. Inspect for fuel leaks.
  9. Install the pickup box. Refer to Pickup Box Replacement in Body Rear End.