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Home >> GMC >> 2006 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 996 (Engine Controls And Fuel - 4.8L, 5.3L, 6.0L, 6.2L, Or 7.0L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2008 GMC Sierra, 2008 GMC Cab & Chassis Sierra, 2008 Chevrolet Silverado, and 2008 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Special Tool On Fuel Tank Module Lock Ring
    GM1854932Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement (15 Reg Cab w/26 Gal Tank)  or Fuel Tank Replacement (25 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Replacement (15 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank)  or Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 gal Tank) .
  2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Reposition the fuel and EVAP pipes out of the way.
  5. Install the J 45722  (1) to the fuel tank module lock ring.
    6. Fig 2: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
    IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
  6. Using the J 45722  and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring.
  7. Remove the J 45722  .
    8. Fig 3: Fuel Pump Module & Lock Ring
    GM1854933Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel tank module lock ring.
    9. NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
  9. Slowly raise the module until the fuel level sensor float arm is just visible.
    10. IMPORTANT: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.
  10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
  11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.
    12. IMPORTANT: DO NOT reuse the old fuel tank module O-ring seal.
  12. Remove and discard the fuel tank module O-ring seal.
    13. Fig 4: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.
    • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
    • Check the lock ring for flatness.
  13. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
  14. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  15. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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