Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 1999-2005

Removal & Installation

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  1. Remove the sending unit.
  2.  
  3. Disconnect the fuel pump electrical connector.
  4.  
  5. Remove the fuel lever sensor electrical connector retaining clip.
  6.  
  7. Disconnect the fuel level sensor electrical connector.
  8.  
  9. Remove the fuel level sensor retaining clip.
  10.  
  11. Remove the fuel level sensor (1).

    Click image to see an enlarged view

    Fig. The fuel level sensor is part of the fuel pump assembly-typical

  12.  

To install:

  1. Install the fuel level sensor (1).
  2.  
  3. Install the fuel level sensor retaining clip.
  4.  
  5. Connect the fuel level sensor electrical connector.
  6.  
  7. Install the fuel lever sensor electrical connector retaining clip.
  8.  
  9. Connect the fuel pump electrical connector.
  10.  
  11. Install the sending unit.
  12.  

4.8L And 5.3L (Lm7 Gasoline) Engines



  1. Remove the fuel tank.
  2.  
  3. Disconnect fuel and evaporative emission (EVAP) lines from the fuel tank module.
    WARNING
    Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage tool Joints. Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

  4.  
  5. Remove the cam lock ring using tool J45722 or equivalent.
  6.  
  7. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fittings below the module cover.
  8.  
  9. Squeeze the quick connect fittings in order to disengage them from the module cover.
  10.  
  11. Remove the fuel tank module from the fuel tank.
  12.  
  13. Remove and discard the fuel tank module seal.
    NOTE
    Important: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.


    NOTE
    Check the lock ring for flatness by placing the lock ring on a flat surface and measuring the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

  14.  

To install:

  1. Install the NEW fuel tank module seal onto the fuel tank.
  2.  
  3. Position the fuel tank module part way into the fuel tank.
  4.  
  5. Connect the quick connect fittings to the module cover.
  6.  
  7. Install the fuel tank module into the fuel tank.
  8.  
  9. Place the cam lock ring into position.
    NOTE
    Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

  10.  
  11. Rotate the cam lock ring clockwise using tool J45722 or equivalent until fully seated.
  12.  
  13. Connect the fuel and EVAP lines to the fuel tank module.
  14.  
  15. Install the fuel tank.
  16.  

5.3L (L59 Flexible Fuel) Engine



  1. Remove the fuel tank.
  2.  
  3. Disconnect the fuel lines from the sending unit, if necessary.
  4.  
  5. Using tool J45722 or equivalent, remove the sending unit lock ring.
  6.  
  7. Remove the lock ring, sending unit, and rubber seal. Discard the seal.
  8.  
  9. Clean the sending unit sealing surfaces.
  10.  

To install:


NOTE
Important: The fuel pump strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, make certain that the fuel pump strainer does not block full travel of the float arm.

  1. Install the sending unit and a NEW rubber seal. Align the alignment tab to the correct location on the fuel tank.
  2.  
  3. Using tool J45722 or equivalent, install the sending unit lock ring.
  4.  
  5. Connect the fuel lines to the sending unit, if necessary.
  6.  
  7. Install the fuel tank.
  8.  

5.7L And 7.4L Engines



  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
  4.  
  5. Drain the fuel tank and remove the tank.
  6.  
  7. Remove the fuel sender assembly.
  8.  
  9. Disconnect the fuel pump electrical connector.
  10.  
  11. Remove the fuel level sensor electrical connector retaining clip.
  12.  
  13. Disconnect the fuel level sensor electrical connector from under the fuel sender cover.
  14.  
  15. Remove the fuel level sensor retaining clip.
  16.  
  17. Squeeze the locking tangs and remove the fuel level sensor.

    Click image to see an enlarged view

    Fig. Fuel pump/fuel level sensor assembly-typical

  18.  

To install:

  1. Install the fuel level sensor.
  2.  
  3. Install the fuel level sensor retaining clip.
  4.  
  5. Connect the fuel level sensor electrical connector.
  6.  
  7. Connect the fuel level sensor electrical connector retaining clip.
  8.  
  9. Connect the fuel pump electrical connector.
  10.  
  11. Install the fuel sender assembly.
  12.  
  13. Refill the fuel tank.
  14.  
  15. Install the fuel filler cap.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Inspect for leaks:

    Turn the ignition switch ON for 2 seconds.
     
    Turn the ignition switch OFF for 10 seconds.
     
    Turn the ignition switch ON .
     
    Check for fuel leaks.
     

  20.  

6.0L And 8.1L Engines (Front Tank)



  1. Remove the front fuel tank.
  2.  
  3. Disconnect fuel and evaporative emission (EVAP) lines from the fuel tank module.
    WARNING
    Notice: DO NOT handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage tool Joints. Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

  4.  
  5. Remove the cam lock ring using tool J45722 or equivalent.
  6.  
  7. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fittings below the module cover.
  8.  
  9. Squeeze the quick connect fittings in order to disengage them from the module cover.
  10.  
  11. Remove the fuel tank module from the fuel tank.
  12.  
  13. Remove and discard the fuel tank module seal.
    NOTE
    Important: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.


    NOTE
    Check the lock ring for flatness by placing the lock ring on a flat surface and measuring the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

  14.  

To install:

  1. Install the NEW fuel tank module seal onto the fuel tank.
  2.  
  3. Position the fuel tank module part way into the fuel tank.
  4.  
  5. Connect the quick connect fittings to the module cover.
  6.  
  7. Install the fuel tank module into the fuel tank.
  8.  
  9. Place the cam lock ring into position.
    NOTE
    Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

  10.  
  11. Rotate the cam lock ring clockwise using tool J45722 or equivalent until fully seated.
  12.  
  13. Connect the fuel and EVAP lines to the fuel tank module.
  14.  
  15. Install the front fuel tank.
  16.  

6.0L And 8.1L Engines (Rear Tank)



  1. Remove the rear fuel tank.
  2.  
  3. Disconnect the evaporative emission (EVAP) lines from the fuel tank module.
    WARNING
    Notice: DO NOT handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage tool Joints. Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

  4.  
  5. Use tool J45722 or equivalent and a long breaker-bar in order to unlock the fuel sender lock ring.
  6.  
  7. Remove the lock ring.
  8.  
  9. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fittings below the module cover.
  10.  
  11. Disconnect the vapor line quick connect fittings in order to remove the module.
  12.  
  13. Remove the module from the fuel tank.
  14.  
  15. Remove and discard the fuel tank module seal.
    NOTE
    Important: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.


    NOTE
    Check the lock ring for flatness by placing the lock ring on a flat surface and measuring the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

  16.  

To install:

  1. Install a NEW fuel tank module seal onto the fuel tank.
  2.  
  3. Position the fuel tank module part way into the fuel tank.
  4.  
  5. Connect the vapor line quick connect fittings to the module.
  6.  
  7. Install the module into the fuel tank.
  8.  
  9. Place the lock ring into position.
    NOTE
    Important: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

  10.  
  11. Using tool J45722 or equivalent, rotate the lock ring clockwise in order to lock the ring.
  12.  
  13. Connect the EVAP lines to the fuel tank module.
  14.  
  15. Install the rear fuel tank.
  16.  

6.5L Engine



  1. Remove the fuel tank filler cap.
  2.  
  3. Disconnect the negative battery cable(s).
  4.  
  5. Raise the vehicle on a hoist.
  6.  
  7. Remove the fuel tank.
  8.  
  9. Remove the sender unit by turning the cam lock counterclockwise using J36608 fuel sender tool or equivalent.
    NOTE
    Important: Do not damage the rubber insulator or the strainer.

  10.  
  11. Remove the sending unit by pulling up.
  12.  
  13. Inspect the attaching hose for signs of deterioration.
  14.  
  15. Inspect the strainer.
  16.  

To install:

  1. Insert a new O-ring seal.
    NOTE
    Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

  2.  
  3. Install the sending unit assembly into the fuel tank.
  4.  
  5. Install the hoses onto the sender assembly.
  6.  
  7. Install the cam lock assembly.
  8.  
  9. Turn the cam lock clockwise in order to lock it.
  10.  
  11. Install the fuel tank. Refer to Fuel Tank Installation.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Check the system for leaks:

    Turn the ignition switch ON for 2 seconds. A scan tool can be used to activate the fuel pump to check for fuel system leaks.
     
    Turn the ignition switch OFFF for 10 seconds.
     
    Turn the ignition switch to the ON position.
     
    Check for fuel leaks.
     

  16.  

 
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