2004 Chevrolet Venture Base, Van Cargo ExtendedFACTORY OEM SERVICE PROCEDURE

Removal Procedure

  1. Remove the fuel tank. Refer to Fuel Tank Replacement (Short Wheel Base)  or Fuel Tank Replacement (Long Wheel Base) .
    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.
  2. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
  3. Disconnect the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    4. Fig 1: View Of Fuel Sender Assembly
    GM51674Courtesy of GENERAL MOTORS CORP.
  4. Use the J 39765 in order to remove the fuel sender assembly retaining ring.
    5. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
  5. Remove the fuel sender assembly and the seal from the fuel tank.
  6. Discard the fuel sender assembly seal.
  7. Clean the fuel sender assembly sealing surfaces.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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