1. Preparation:
* Safety First: Work in a well-ventilated area. Gasoline fumes are highly flammable. Use appropriate safety glasses and gloves.
* Gather Tools: You'll need various tools depending on your truck's configuration, but expect to need:
* Socket wrench set (metric and possibly standard)
* Screwdrivers (Phillips and flathead)
* Pliers
* Fuel line disconnect tool (if applicable)
* A helper (highly recommended for the weight of the fuel tank)
* Jack and jack stands (or ramps)
* Shop rags or absorbent material
* New fuel sending unit (obviously!)
* Possibly a new gasket (depending on the condition of the old one)
* Safety glasses and gloves
* Drain the Fuel Tank: This is crucial. Siphon or pump out as much fuel as possible. You might need to remove the fuel pump to completely empty the tank, especially if the sender unit is integrated.
2. Accessing the Fuel Tank:
* Lowering the Tank: This is often the most challenging part. You'll likely need to:
* Securely support the truck with jack stands. Never work under a vehicle supported only by a jack.
* Locate the fuel tank straps. They are usually near the rear of the tank.
* Carefully loosen and remove the fuel tank straps. This may involve removing some body panels or other components for access. Consult a repair manual for your specific model.
* Lower the tank carefully. It's heavy and contains some residual fuel. A helper is strongly recommended.
* Alternative Access (Less Common): Some models might allow access to the sending unit through an access hole in the bed of the truck. Check your repair manual for this possibility.
3. Removing the Old Sending Unit:
* Disconnect Electrical Connections: Disconnect the electrical connector(s) from the old sending unit.
* Remove Fuel Lines: Carefully disconnect the fuel lines from the sending unit. Use the correct fuel line disconnect tool to prevent damage. Be prepared for some fuel spillage, even if you've drained the tank.
* Remove the Sending Unit: The sending unit is usually held in place by a retaining ring or bolts. Carefully remove these fasteners and lift the unit out of the tank.
4. Installing the New Sending Unit:
* Inspect the Tank: Inspect the tank for rust, damage, or debris. Clean it thoroughly if necessary.
* Install the Gasket (If Needed): If your kit includes a new gasket, install it on the tank opening.
* Install the New Sending Unit: Carefully lower the new sending unit into the tank, ensuring it's seated properly.
* Secure the Sending Unit: Replace the retaining ring or bolts. Tighten them securely, but avoid over-tightening.
* Reconnect Fuel Lines: Carefully reconnect the fuel lines, ensuring a snug and leak-free connection.
* Reconnect Electrical Connections: Reconnect the electrical connector(s) to the new sending unit.
5. Reinstalling the Fuel Tank:
* Raise the Fuel Tank: Carefully raise the fuel tank back into its position.
* Secure the Fuel Tank: Reattach the fuel tank straps.
* Reconnect any other disconnected components.
6. Testing:
* Reconnect the battery.
* Check for Leaks: Carefully inspect all fuel connections for leaks.
* Test the Gauge: Start the engine and check if the fuel gauge is working correctly.
Important Notes:
* Consult a Repair Manual: This is crucial. A factory service manual for your specific year, make, and model of Chevrolet pickup will provide detailed diagrams and instructions. This is far more reliable than generic instructions.
* Fuel Safety: Remember that gasoline is highly flammable and explosive. Work in a well-ventilated area and take all necessary precautions.
* If Unsure, Seek Professional Help: If you are not comfortable performing this task, it is best to take your vehicle to a qualified mechanic.
This is a general overview; specific steps may vary. Always prioritize safety and consult a repair manual for your particular vehicle. Improper installation could lead to fuel leaks, fire hazards, and damage to your vehicle.
