GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 300138  Size: SH

    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.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

  5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Clean all fuel and evaporative emission (EVAP) pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
  7. Remove the fuel tank. Refer to Fuel Tank Replacement .

  8. Object Number: 396067  Size: SH
  9. Remove the rear fuel feed pipe (4) and the rear fuel return pipe (5) from the fuel sender (2) and the fuel tank clips (6).
  10. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

Installation Procedure


    Object Number: 396067  Size: SH
  1. Remove the caps from the fuel and EVAP pipes.
  2. Connect the rear fuel feed pipe (4) and the rear fuel return pipe (5) to the fuel sender (2) and the fuel tank clips (6).

  3. Object Number: 300138  Size: SH
  4. Install the fuel tank. Refer to Fuel Tank Replacement .
  5. Lower the vehicle.
  6. Refill the fuel tank.
  7. Tighten the fuel filler cap.
  8. Connect the negative battery cable.
  9. Inspect for leaks.
  10. 8.1. Turn the ignition ON for 2 seconds.
    8.2. Turn the ignition OFF for 10 seconds.
    8.3. Turn the ignition ON.
    8.4. Inspect for fuel leaks.