Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2005CHEVY EXPRESS G3500, VAN PASSENGER, LQ4REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 1 (ENGINE CONTROL SYSTEM - 4.3L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK PUMP MODULE REPLACEMENTINSTALLATION PROCEDURE

2005 Chevrolet Chevy Express G3500, Van Passenger, LQ4

Installation Procedure

2005 Chevrolet Chevy Express G3500, Van Passenger, LQ4SECTION Installation Procedure

WARNING: This page is about a different variant/trim than selected.

Fig 1: Identifying Fuel Sender Assembly

Courtesy of GENERAL MOTORS CORP.

Install the fuel pressure sensor (1).
Install the fuel level sensor (3).
Install the retaining clip (4) to the fuel level sensor.
Connect the electrical connector (7) to the fuel level sensor.
Connect the electrical connector retaining clip (6).
Connect the fuel pump electrical connector (5).
IMPORTANT: Always install a new fuel strainer when replacing the fuel tank fuel pump module.
Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
Install the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Side Tank) or Fuel Tank Replacement (Passenger/Cargo Van) or Fuel Tank Replacement (Cutaway Van Rear Tank) .
Refill the fuel tank.
Tighten the fuel filler cap.
Connect the negative battery cable.
Inspect for leaks:
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.

RENDER: 1.0x

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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.