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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 947 (Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction)) >> Repair Instructions >> Fuel Sender Assembly Replacement (5.3L (L59) Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
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.
IMPORTANT: The fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm.
  1. Install a NEW sending unit seal.
  2. Align the tab, and install the sending unit.
    3. Fig 1: Fuel Sender Assembly (5.3L (L59))
    GM871951Courtesy of GENERAL MOTORS CORP.
  3. Using J 44402  , install the sending unit lock ring.
    4. Fig 2: Removing/Installing Sending Unit Lock Ring (5.3L (L59))
    GM871947Courtesy of GENERAL MOTORS CORP.
  4. Connect fuel lines to the sending unit, if required. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  5. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup)  or Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)  or Fuel Tank Replacement (1500 Crew Cab)  or Fuel Tank Replacement (Cab/Chassis - Front)  or Fuel Tank Replacement (Cab/Chassis - Rear) .
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