GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

  1. Remove the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Drain fuel tank. Refer to Fuel Tank Draining .
  4. Remove the fuel tank. Refer to Fuel Tank Replacement .

  5. Object Number: 54674  Size: SH

    Important: 

       • The modular fuel sender assembly may spring up from its position.
       • When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one.
       • Carefully discard the reservoir fuel into an approved container.

  6. While holding the modular fuel sender assembly down, remove the snap ring from designated slots located on the retainer.

Installation Procedure


    Object Number: 54674  Size: SH
  1. Install a new O-ring on the modular fuel sender to the tank.
  2. Align the tab on front of the modular sender with slot on front of the retainer snap ring.
  3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.
  4. Important: Be sure that the snap ring is fully seated within the tab slots.

  5. Insert snap ring into designated slots.
  6. Install the fuel tank. Refer to Fuel Tank Replacement .
  7. Lower the vehicle.
  8. Refill the fuel tank.
  9. Inspect for fuel leaks through the following steps:
  10. 8.1. Turn the ignition switch to the ON position for 2 seconds.
    8.2. Turn the ignition switch to the OFF position for 10 seconds.
    8.3. Turn the ignition switch to the ON position
    8.4. Check for fuel leaks.