Chevrolet Impala:

Removing the Fuel Pump

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#1 5/29/2010 1:45 PM

Ritchy
Senior Member
Registered: 5/13/2010
Posts: 60

Removing the Fuel Pump

How do you remove the retaining ring holding the fuel sender/pump assembly to the fuel tank on a 2002 Chevy Impala 3.8L?

Thanks.

Last edited by Ritchy (5/29/2010 1:47 PM)

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#2 5/29/2010 4:39 PM

TechHelp2
Administrator
Registered: 11/23/2009
Posts: 1033

Re: Removing the Fuel Pump

FUEL SENDER ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE

CAUTION: fuel vapors can collect while servicing fuel system parts in enclosed a mask such as a trunk. To reduce the risk of fire and increased exposure to vapors:                     

Use forced air ventilation such as a fan set outside of the trunk.
Plug or cap any fuel system openings in order to reduce fuel vapor formation.
Clean up any spilled fuel immediately.
Avoid sparks and any source of ignition.
Use signs to alert others in the work area that fuel system work is in process.

NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
The fuel pipe connections
The hose connections
The areas surrounding the connections

IMPORTANT: Always maintain cleanliness when servicing fuel system components.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the spare tire cover, the jack, and the spare tire.
3. Remove the rear compartment trim panel.
4. Remove the nuts retaining the fuel sender access panel.
5. Remove the fuel sender access panel.
6. Disconnect the fuel tank pressure sensor electrical connector.
7. Disconnect the fuel sender electrical connector.
8. Clean the fuel pipes, and fuel sender assembly to prevent possible fuel contamination during removal.
9. Disconnect the quick-connect fittings at the fuel sender assembly. IMPORTANT: The modular fuel sender assembly will spring-up when the snap ring is removed.
10. Remove the fuel sender retaining ring.
11. Remove the modular fuel sender assembly.
12. Clean the fuel sender assembly sealing surfaces.
13. Inspect the fuel sender assembly sealing surfaces.

INSTALLATION PROCEDURE

NOTE: Refer to Fuel System Ground Notice in Service Precautions.

IMPORTANT:
Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.
Be sure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.
Always replace the fuel sender seal when reinstalling the fuel sender assembly.

1. Position the new fuel sender assembly seal on the fuel tank.
2. Place the fuel sender assembly into the fuel tank.
3. Install the fuel sender assembly retaining snap ring, while holding the sender assembly in place.
4. Connect the fuel sender electrical connector.
5. Connect the fuel tank pressure sensor electrical connector.
6. Connect the quick-connect fittings at the fuel sender assembly.
7. Connect the negative battery cable.
8. Turn on ignition for 2 seconds.
9. Turn off ignition for 10 seconds.
10. Turn on ignition.
11. Look for fuel leaks.

Install the fuel sender access panel. NOTE: Refer to Fastener Notice in Caution and Notices.
Reinstall the 7 nuts retaining the fuel sender access panel.Tighten the fuel sender access panel nuts to 10 N.m (89 lb in).
Install the rear compartment trim panel.
Install the spare tire, the jack, and the spare tire cover

WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury:

1. Keep a dry chemical (Class B) fire extinguisher near the work area.
2. Place a "CAUTION FLAMMABLE" sign in the work area.
3. Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away.
4. Wear eye protection.
5. Use caution when working near the  catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).
6. Relieve the fuel system pressure prior to disconnecting fuel system components.
7. Disconnect the negative battery cable except for tests where battery voltage is required.
8. Use a suitable container to store or catch fuel.
9. Do not replace fuel pipe with fuel hose.
10. Plug all disconnected fuel line fittings and hoses.
11. After making any fuel system repairs ALWAYS inspect for fuel leaks.

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#3 5/31/2010 1:49 PM

Ritchy
Senior Member
Registered: 5/13/2010
Posts: 60

Re: Removing the Fuel Pump

Excellent. Thanks a lot TechHelp2.

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#4 5/31/2010 6:07 PM

TechHelp2
Administrator
Registered: 11/23/2009
Posts: 1033

Re: Removing the Fuel Pump

Glad we could help. We are here if you need us in the future.


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