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HOMESERVICE MANUALSGMC1999FORWARD CONTROL 5.7 R, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 94 (ENGINE CONTROLS REMOVAL & INSTALLATION)FUEL SYSTEMS (GASOLINE ENGINES)FUEL SENDER ASSEMBLYREMOVAL & INSTALLATION
1999 GMC Forward Control 5.7 R, Automatic

Removal & Installation

1999 GMC Forward Control 5.7 R, AutomaticSECTION Removal & Installation
WARNING: This page is about a different car, the 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Fuel sender assembly is located in fuel tank. See Fig 1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE (GASOLINE) . Remove fuel tank. See FUEL TANK (GASOLINE) .
    Fig 1: Locating Fuel Sender Assembly
    G00129191Courtesy of GENERAL MOTORS CORP.
    2. CAUTION: The fuel sender assembly may spring up when removing. The fuel sender assembly reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float. Carefully discard the reservoir fuel into an approved container.
  2. Disconnect the wiring harness from the fuel sender assembly and the fuel tank pressure sensor. Using Fuel Sender Lock Nut Wrench (J 39765), press down and rotate the retainer. Lift the fuel sender assembly from fuel tank.
  3. To install, reverse removal procedure using new gasket. Tighten components to specification. See TORQUE SPECIFICATIONS . Inspect for leaks by using the following procedure:
    • Turn ignition on for 2 seconds.
    • Turn ignition off for 10 seconds.
    • Turn ignition on.
    • Check for fuel leaks.
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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.