GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 45722 Fuel sender Wrench
    • EN-48278 Sub-Fuel Pump Lock Ring Removal/Installation Tool
    • J 45004 Fuel Tank Drain Hose

Important: 

   • Only use oil free compressed air to blow out the fuel pipes.
   • Inspect the fuel tank internally and clean the fuel tank if you find a plugged fuel filter.

    Caution: Refer to Battery Disconnect Caution in the Preface section.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Remove the fuel tank. Refer to Fuel Tank Replacement .
  5. Remove the fuel module assemblies. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .
  6. Inspect the fuel pump strainer. Replace the contaminated strainer and inspect the fuel pump.
  7. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet.
  8. Important: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations.

  9. Flush the fuel tank with hot water.
  10. Pour the water out of the fuel sender assembly opening. Rock the tank to make sure that all water is removed from the tank.
  11. Install the fuel module assemblies. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .
  12. Install the fuel tank. Refer to Fuel Tank Replacement .
  13. Refill the fuel tank.
  14. Install the fuel filler cap.
  15. Connect the negative battery cable.
  16. 14.1. Turn ON the ignition for 2 seconds.
    14.2. Turn OFF the ignition for 10 seconds.
    14.3. Turn ON the ignition.
    14.4. Inspect for fuel leaks.