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Home >> Buick >> 2009 >> Lucerne CXL, 3.9 1 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 3.9L - Introduction >> Repair Instructions >> Fuel Tank Module Replacement (NU6) >> Installation Procedure
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Installation Procedure

    Fig 1: View Of Fuel Level Sensor Float Arm
    GM1755112Courtesy of GENERAL MOTORS CORP.
  1. Place a NEW fuel pump sender O-ring seal onto the fuel tank.
    2. NOTE: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.
  2. Tilt the sender toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the sender into the fuel tank.
  3. Lower the sender assembly into the tank.
    4. Fig 2: Identifying Vapor Line Quick Connect Fittings
    GM1755111Courtesy of GENERAL MOTORS CORP.
  4. Connect the internal vent line quick connect fittings (1 and 2) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Remove the string securing the internal vent lines.
  6. Install the sender lock ring, and move it into position on the top of the sender.
    7. Fig 3: Identifying Vent Line Quick Connect Fitting
    GM1755110Courtesy of GENERAL MOTORS CORP.
  7. Connect the vent line quick connect fitting (1) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .
    8. Fig 4: View Of Special Tool On Lock Ring
    GM1755109Courtesy of GENERAL MOTORS CORP.
  8. Install the J 45722  to the lock ring. See Special Tools .
    9. Fig 5: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    NOTE: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.
    Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  9. Using the J 45722  and a breaker bar, rotate the fuel sender lock ring clockwise until the ring is locked into place on the fuel tank. See Special Tools .
  10. Remove the J 45722  . See Special Tools .
    11. Fig 6: View Of Fuel Feed Pipe & Harness Connector
    GM1755108Courtesy of GENERAL MOTORS CORP.
  11. Position the fuel feed pipe and harness connector.
  12. Connect the EVAP line quick connect fitting (1) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .
  13. Connect the fuel feed rear pipe quick connect fitting (3) to the sender. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the fuel level sensor wiring harness electrical connector (4) to the sender.
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  16. Perform the following procedure in order to inspect for leaks:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
    17. Fig 7: Identifying Fuel Sender Access Hole Cover
    GM1671970Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel sender access hole cover.
    18. CAUTION: Refer to Fastener Caution .
  18. Install the fuel sender access hole cover bolts and tighten to 2 N.m (18 lb in)
  19. Install the rear compartment liner. Refer to Rear Compartment Trim Panel Replacement .
  20. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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