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

Removal Procedure

    Object Number: 21304 Size: SH
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
  3. Drain the fuel tank. Refer to Draining Fuel Tank.
  4. Remove the fuel tank. Refer to Fuel Tank and Fuel Filler Pipe Replacement.
  5. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.
  6. Note the position of the fuel strainer (9) on the fuel pump (7).
  7. Support the fuel sender assembly (6) with one hand and grasp the strainer (9) with the other hand.
  8. Rotate the strainer in one direction and pull the strainer off the pump. Discard the strainer after inspection.
  9. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
  10. Inspect the fuel pump inlet for dirt and debris. If found, replace the fuel pump.
  11. If the fuel pump is being replaced, proceed to Step 12.
  12. Loosen the clamp (4) and remove the fuel feed hose (3) from the fuel pump outlet.
  13. Remove the terminal retainer.
  14. Disconnect the fuel pump electrical connector and the electrical connector from the bottom of the sender cover.
  15. Remove the retainer clip (1) from the fuel return pipe.
  16. Remove the fuel pump and fuel level sensor assembly and the spring (2) from the fuel sender.
  17. Remove the housing cover (5) from the fuel pump housing (8).
  18. Remove the fuel pump (7) from the fuel pump housing (8).

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

  19. If the fuel level sensor is being replaced, proceed to Step 20.
  20. Slide the fuel level sensor (10) from the retainers on the fuel pump housing (8).

Installation Procedure

    Object Number: 21304 Size: SH
  1. Install the fuel level sensor (10) to the fuel pump housing (8).
  2. Install the fuel pump (7) and the isolator into the fuel pump housing (8).

    3. Important: The small hole in the housing cover (5) aligns over the fuel level sensor (10).

  3. Install the housing cover (5) to the fuel pump housing (8).
  4. Slide the fuel pump and fuel level sensor assembly and spring (2) onto the fuel return pipe.

    5. Important: The fuel pump and fuel level sensor assembly must be aligned directly under the fuel sender cover.

  5. Compress the spring (2) and install the retainer clip (1) through the fuel return pipe.
  6. Connect the fuel feed hose (3) to the fuel pump outlet. Tighten the clamp (4) so that 5 to 8 teeth are engaged.
  7. Connect the fuel pump electrical connector and the electrical connector to the bottom of the sender cover.
  8. Install the terminal retainer.

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

  9. 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.
  10. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.
  11. Install the fuel tank. Refer to Fuel Tank and Fuel Filler Pipe Replacement.
  12. Add fuel.
  13. Install the fuel filler cap.
  14. Connect the negative battery cable.
  15. Inspect for leaks.
    16. 15.1. Turn the ignition switch ON for 2 seconds.
    15.2. Turn the ignition switch OFF for 10 seconds.
    15.3. Turn the ignition switch ON.
    15.4. Check for fuel leaks.