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.
SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2004AVALANCHE 2500 2WD V8-8.1L VIN GREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTCOMPUTERS AND CONTROL SYSTEMSFUEL LEVEL SENSORSERVICE AND REPAIRFUEL SENDER ASSEMBLY REPLACEMENT (FRONT TANK)
2004 Chevrolet Avalanche 2500 2WD V8-8.1L VIN G
Fuel Sender Assembly Replacement (Front Tank)
2004 Chevrolet Avalanche 2500 2WD V8-8.1L VIN GSECTION Fuel Sender Assembly Replacement (Front Tank)
FUEL SENDER ASSEMBLY REPLACEMENT (FRONT TANK)
TOOLS REQUIRED
J 45722 Fuel Sender Lock Ring Wrench
REMOVAL PROCEDURE
1. Remove the front fuel tank.
2. Disconnect the fuel and evaporative emission (EVAP) lines from the fuel tank module.
3. Using J 45722, rotate the lock ring counterclockwise in order to unlock the ring.
IMPORTANT: Ensure that the tool does not come in contact with the module pipes while unlocking the lock ring.
4. Remove J 45722 and the lock ring.
5. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fitting below the module cover.
6. Disconnect the vapor line quick connect fitting (1) in order to remove the module.
7. Remove the module from the fuel tank.
8. Remove and discard the fuel tank module seal.
INSTALLATION PROCEDURE
1. Install a NEW fuel tank module seal onto the fuel tank.
2. Position the fuel tank module part way into the fuel tank.
3. Connect the vapor line quick connect fitting (1) to the module.
4. Install the module into the fuel tank.
5. Place the lock ring into position.
6. Using J 45722, rotate the lock ring clockwise in order to lock the ring.
IMPORTANT: Ensure that the tool does not come in contact with the module pipes while locking the lock ring.
7. Connect the fuel and EVAP lines to the fuel tank module.
8. Install the front fuel tank.
RENDER: 1.0x
NO RELATED
Recommended Tools & Savings
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Affiliate disclosure: We may earn a commission at no extra cost to you.
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.