GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

  1. Remove the fuel tank from the vehicle. Refer to Fuel Tank Replacement .
  2. Remove the fuel gauge sender and pump unit. Refer to Fuel Sender Assembly Replacement .
  3. Remove all remaining fuel from the tank.
  4. Inspect the fuel tank for any remaining fuel.

Cleaning Procedure

Important: 

   • Use only oil free compressed air to blow out the fuel pipes.
   • If the in-line fuel filter is plugged, inspect the fuel tank internally and purge if necessary.

  1. Clean the fuel lines by applying air pressure in the opposite direction of fuel flow.
  2. Install tap water into the tank.
  3. • Move the tank to the flushing area (wash rack).
    • Agitate the water vigorously and then drain it.
  4. Install a gasoline emulsifying agent into the tank. Use an available emulsifying agent, such as Product-Sol No. 913 or the equivalent.
  5. Add water to the fuel tank.
  6. • Refer to the emulsifying agent specifications for the mixture ratio.
    • Fill the tank with water until it overflows.
    • Agitate the mixture for ten minutes.
    • Drain the tank completely.
    • Completely flush out any remaining mixture.
    • Drain the fuel tank.

Installation Procedure

  1. Install the fuel gage sending and pump unit. Refer to Fuel Sender Assembly Replacement .
  2. Install the fuel tank into the vehicle. Refer Fuel Tank Replacement .

Inspection Procedure

Important: The fuel tank filler neck clamps must be properly positioned and aligned. Otherwise, the filler neck may become disconnected from the fuel tank.

Turn the ignition switch ON for two seconds then turn the switch OFF for ten seconds. Again turn the ignition switch ON and check for fuel leaks.