GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Tools Required

    •  J 34730 Fuel Pressure Gauge
    •  J 39765 Fuel Sender Lock Nut Wrench

Important: Only use oil free compressed air to blow out fuel pipes. If the in-pipe fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary.

  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .

  2. Object Number: 211302  Size: SH
  3. Drain the (1) fuel tank. Refer to Fuel Tank Draining .

  4. Object Number: 386183  Size: SH
  5. Remove the fuel tank (4). Refer to Fuel Tank Replacement .
  6. Important: When ever the fuel tank is cleaned, the fuel pump fuel strainer must be inspected. If the fuel pump fuel strainer is contaminated, the fuel pump fuel strainer must be replaced and the fuel pump must be inspected. The fuel pump inlet for dirt and debris. If dirt and debris are found, the fuel pump should be replaced.


    Object Number: 191412  Size: SH
  7. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

  8. Object Number: 65628  Size: SH

    Important: When flushing the fuel tank, the fuel and water mixture needs to be treated as a hazardous material. The material needs to be handled in accordance with all local, state, and federal regulations.

  9. Flush the fuel tank with hot water.
  10. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete.

Installation Procedure


    Object Number: 191412  Size: SH
  1. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

  2. Object Number: 386183  Size: SH
  3. Install the fuel tank (4). Refer to Fuel Tank Replacement .
  4. Add fuel and install the fuel tank filler pipe cap.
  5. Connect the negative battery cable. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in Cautions and Notices.
  6. Inspect for leaks.
  7. 5.1. Turn the ignition switch On for 2 seconds.
    5.2. Turn the ignition switch Off for 10 seconds.
    5.3. Turn the ignition switch On.
    5.4. Check for fuel leaks.
  8. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement .