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Tahoe / Yukon Service Manual

Fuel Level Sensor Replacement (Short Wheelbase) (1)

Fuel Level Sensor Replacement (Short Wheelbase) Single Use Fasteners and Components Fuel Sender Seal Special Tools CH–45722 Fuel Sender Lock Ring Wrench Equivalent regional tools: Special Tools

  1. Drain the fuel tank. Fuel Tank Draining
  2. Raise and support the vehicle. Lifting and Jacking the Vehicle
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 1
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 1
  1. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Remove [4x]
  2. Remove both rear stabilizer shaft clamp (2) from the frame and let the stabilizer shaft hang.
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 2
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 2
  1. Fuel Feed Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
  2. Fuel Return Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 3
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 3
  1. Fuel Tank Filler Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
  2. Fuel Tank Filler Hose Clamp (2) » Loosen
  3. Fuel Tank Filler Hose (3) » Remove
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 4
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 4
  1. Place a suitable adjustable jack under the fuel tank.
  2. Strap fuel tank to jack.
  3. Fuel Tank Strap Bolt (1) » Remove [2x]
  4. Fuel Tank Strap (2) » Remove [2x]
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 5
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 5
  1. Lower the fuel tank, allowing clearance to access connections at the top of the tank.
  2. Electrical Connector (1) » Disconnect
  3. Fuel Feed Hose Clip (2) » Disengage
  4. Wiring Harness Retainer (3) » Disengage
  5. Retainer (4) » Unclip
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 6
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 6
  1. Fuel Tank (1) » Remove
  2. Remove the straps holding the fuel tank to the jack.
  3. Remove the jack.
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 7
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 7
  1. Fuel Return Hose (1) » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service
  2. Fuel Feed Hose (2) » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service
  3. Fuel Tank Filler Vent Hose (3) » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 8
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 8
  1. Fuel Sender Retainer (1) » Remove — CH–45722 Fuel Sender Lock Ring Wrench(2)
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 9
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 9
  1. Fuel Tank Fuel Pump Module (1) » Remove
  2. Fuel Sender Seal (2) » Remove and DISCARD
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 10
Fuel Level Sensor Replacement (Short Wheelbase) (1) — figure 10

  1. Disconnect the fuel level sensor electrical connector.

  2. Fuel Level Sensor (1) » Remove Installation Procedure

  3. Fuel Level Sensor (1) » Install

  4. Connect the fuel level sensor electrical connector.

  5. Fuel Sender Seal (2) » Install NEW

  6. Fuel Tank Fuel Pump Module (1) » Install

  7. Fuel Sender Retainer (1) » Install — CH–45722 Fuel Sender Lock Ring Wrench(2)

  8. Fuel Tank Filler Vent Hose (3) » Connect — Plastic Collar Quick Connect Fitting Service

  9. Fuel Feed Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

  10. Fuel Return Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

  11. Place a suitable adjustable jack under the fuel tank.

  12. Strap fuel tank to jack.

  13. Raise the fuel tank  (1), allowing access to connections at the top of the tank.

  14. Retainer (4) » Clip

  15. Wiring Harness Retainer (3) » Engage

  16. Fuel Feed Hose Clip (2) » Engage

  17. Electrical Connector (1) » Connect

  18. Raise the tank to the installed position.

  19. Remove the straps holding the fuel tank to the jack.

  20. Fuel Tank Strap (2) » Install [2x]

  1. Fuel Tank Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications

  2. Remove the jack.

  3. Fuel Tank Filler Hose (3) » Install

  4. Fuel Tank Filler Hose Clamp (2) » Tighten — Fastener Specifications

  5. Fuel Tank Filler Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

  6. Fuel Return Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

  7. Fuel Feed Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

  8. Raise rear stabilizer shaft into installed position.

  9. Rear Stabilizer Shaft Clamp (2) » Install [2x]

  10. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Install and tighten [4x] — Fastener Specifications

  11. Lower the vehicle.

  12. Refill the fuel tank.

  13. Prime the fuel system and inspect for fuel leaks. Fuel System Priming