GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Corvette 🢒 Engine 🢒 Engine Controls - 4.3L (Caprice Only) and 5.7L 🢒 Fuel Sender Assembly Service

Removal Procedure

    Object Number: 13649 Size: SH
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
  3. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.
  4. Note the position of the fuel strainer on the fuel pump.
  5. Support the fuel sender assembly with one hand and grasp the strainer with the other hand.
  6. Rotate the strainer in one direction and pull the strainer off the pump. Discard the strainer after inspection.
  7. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
  8. Inspect the fuel pump inlet for dirt and debris. If found, replace the fuel pump.
  9. If the fuel pump is being replaced, proceed to Step 10.
  10. Disconnect the fuel pump electrical connector.
  11. Place the fuel sender assembly upside down on a bench.
  12. Pull the fuel pump downward to remove it from the mounting bracket, then tilt the pump outward and remove it from the fuel pulse dampener.

    13. Notice: Do not run the fuel pump unless the fuel pump is submerged in fuel in order to prevent damage to the fuel pump.

  13. If the fuel pulse dampener is being replaced, proceed to Step 14.
  14. Note the position of the fuel pulse dampener on the inlet tube.
  15. Remove the fuel pulse dampener from the inlet tube.
  16. Dry the fuel pulse dampener with a shop towel.
  17. Shake the fuel pulse dampener while listening for trapped fuel movement inside the fuel pulse dampener.
  18. If you hear fuel inside the fuel pulse dampener, replace the fuel pulse dampener.
  19. If the fuel sender is being replaced, proceed to Step 20.
  20. Transfer the fuel pump and the fuel pulse dampener to the new fuel sender.

Installation Procedure

    Object Number: 13649 Size: SH
  1. Install the fuel pulse dampener in the same position as noted during disassembly.
  2. Install the rubber bumper and the rubber insulator on the fuel pump.
  3. Position the fuel sender assembly upside down.
  4. Install the fuel pump between the fuel pulse dampener and the mounting bracket.
  5. Connect the fuel pump electrical connector.

    6. Important: Always install a new pump strainer when replacing the fuel pump.

  6. Install a new fuel pump strainer in the same position as noted during disassembly. Push on the outer edge of the strainer ferrule until the strainer is fully seated.
  7. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.
  8. Connect the negative battery cable.
  9. Inspect for leaks.
    10. 9.1. Turn the ignition switch ON for 2 seconds.
    9.2. Turn the ignition switch OFF for 10 seconds.
    9.3. Turn the ignition switch ON.
    9.4. Check for fuel leaks.