Fuel Pump - Fuel Sender Assembly - Replacement Procedure

[Astrophysics]

Hi,

By putting Astro front and rear up on ramps, there is lots of clearance to work, especially since my 2003 also has the 2" body lift, and coil over shocks in rear.
I used Harbor Freight motorcycle Jack to support tank. It works great.

See photos.

One photo shows the EVAP solenoid box hanging by the vapor line.
So far all of the quick connect fitting were pretty easy to release. I sprayed the fittings with Silicine spray lube prior to removing to lube the little O rings too.

Also, I had disconnected the fuel filter and the metal hard line coupler near the filter.
Caution, there are O rings in the metal threaded coupler. O rings appear OK , but I may replace them anyway.

AP

[Astrophysics]

Hi,

Fuel to the People!

<Off topic content removed. I asked you nicely at New Years to keep it out of the technical section please. - MMJ>

I ordered a replacement rubber filler hose since I damaged the end of original with flat blade screwdriver on removal.

On line $18 from Filler Neck supply.

On the 2003 Astro , it is 5 1/2" long rubber hose with taper to have 1" OD on the fill side and 1 1/4" ID on tank end.

The replacement hose is straight 1 1/4 ‘ I D hose with a rubber reducer on one end to get the 1" ID.

AP

[Astrophysics]

Hi,

New pump installed. Now, I can re install tank.

AP

[Astrophysics]

Hi,

Astro runs great now with new fuel pump.

<irrelevant information removed>

AP

[Bret Schmerker]

@Astrophysics Congrats on a successful pump replacement. I's considering the MU1380 (General Motors Corp. P/N# 15036173) as a stock upgrade for my M11006 three years ago.

[Astrophysics]

Hi,

The Astro tank is actually easier to remove than the ones on the Tahoe and Yukon. The super long strap M10 1.5 mm pitch, bolts are 70 mm long which lets one lower the straps about 1 1/2 inches to allow the Fuel and Return quick connectors to be released before lowering the tank. The OEM bolts were captivated by the slightly tight fit hole in strap. This made it difficult to finger tight the bolts. I used a round file to enlarge the holes then used plastic clips to captivate the bolts, and allow easy spin of bolts on reassembly. Lube the bolts and threaded inserts with Silicon spray.

The spacing between the straps is just wide enough to fit the rubber padded arms of the motorcycle Jack to fit,

My favorite new accessories was the WD 40 brand Silicone spray lube to spray on fuel line quick disconnects to lube the O. Rings.

The WD 40 spray can has the attached folding spray nozzle.

AP