Fuel Sender Assembly Replacement for Chevrolet Chevrolet C-Series Medium Duty Truck B7 2000

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief
3. Drain the fuel tank. Refer to Fuel Tank Draining .



4. Remove the fuel tank (2) and sender assembly (1). Refer to Fuel Tank Replacement - Left Side or Fuel Tank Replacement - Right Side .

1. Note the position of the fuel pump strainer (3) on the fuel pump (4).
2. Support the pump (4) with one hand and grasp the strainer (3) with the other hand.
3. Rotate the strainer in one direction and pull off the pump (4). Discard the strainer after inspection.
4. Inspect the fuel pump strainer (3). Replace the strainer if it has contaminates and clean the fuel tank.
5. Inspect the fuel pump inlet for dirt and debris. If found, replace the pump.

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Push on the outer edge of the ferrule until fully seated.
2. Support the pump (4) with one hand and position the new pump strainer (3) on pump in the same position as noted during disassembly.

1. Install a new seal, sending assembly (2) and lock ring (8). Make sure the lock ring alignment holes fit over the tabs on the tank.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the six nuts and washers (1) retaining the fuel sender lock ring (8).

Tighten
Tighten the lock ring nuts to 11.5 N·m (100.90 lb in).

3. Install the fuel tank. Refer to Fuel Tank Replacement - Left Side or Fuel Tank Replacement - Right Side .
4. Add fuel to the tank.
5. Connect the negative battery cable.
6. Check for fuel leaks.

6.1.	Turn the ignition ON for 2 seconds.

6.2.	Turn OFF the ignition for 10 seconds.

6.3.	Again, turn the ignition switch to the ON position.

6.4.	Check for fuel leaks.