LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Chevrolet >> 2005 >> Impala LS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 3.8L (L36 And L67) - Introduction (2 Of 2) >> Repair Instructions >> Fuel Sender Assembly Replacement >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

    NOTE: Refer to Fuel System Ground Notice in Cautions and Notices.
    IMPORTANT: Care should be taken not to 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 float arm.
    IMPORTANT: Ensure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.
    Fig 1: View Of Fuel Sender Retaining Ring
    GM66012Courtesy of GENERAL MOTORS CORP.
  1. Position the new fuel sender assembly O-ring on to the fuel tank.
  2. Install the fuel sender assembly into the fuel tank.
  3. Install the fuel sender assembly retaining ring while holding the fuel sender assembly down.
  4. Connect the fuel sender electrical connector.
  5. Connect the fuel tank pressure sensor electrical connector.
  6. Connect the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Install the fuel tank to a transmission jack.
    8. Fig 2: View Of Fuel Tank
    GM699556Courtesy of GENERAL MOTORS CORP.
  8. Raise the fuel tank (1) to the original position.
    9. NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install the fuel tank strap bolts (2).

    Tighten:  Tighten the bolts to 47 N.m (35 lb ft).

  10. Remove the transmission jack.
    11. Fig 3: View Of Fuel Tank Shield
    GM699555Courtesy of GENERAL MOTORS CORP.
  11. Install the fuel tank shield (3).
  12. Install the fuel tank shield push pins (2).
    13. Fig 4: View Of Fuel Feed & Return Pipes
    GM32401Courtesy of GENERAL MOTORS CORP.
  13. Connect the quick-connect fittings at the fuel filter area. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  14. Connect the EVAP pipe at the front of the fuel tank.
    15. Fig 5: View Of EVAP Fresh Air Hose
    GM698635Courtesy of GENERAL MOTORS CORP.
  15. Connect the EVAP fresh air hose at the splice.
    16. Fig 6: View Of Fuel Tank Filler Hose
    GM155468Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel tank filler hose to the fuel tank.
    17. Fig 7: Identifying Fuel Tank Components
    GM186674Courtesy of GENERAL MOTORS CORP.
  17. Fully seat the filler hose (4) on the fuel tank port (2).
  18. Ensure the clamp (1) is properly located on the tank port between the bead (5) and the tank (3).

    Tighten:  Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).

  19. Install the exhaust pipe hangers.
  20. Lower the vehicle.
  21. Add fuel and install the fuel filler pipe cap.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  23. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, for 2 seconds.
    2. Turn OFF the ignition, for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
scientia non olet · About LEMON Manuals