Removal Procedure

WARNING:

Refer to Gasoline/Gasoline Vapors Warning .

WARNING:

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.

Fig 1: Identifying Fuel Sender Access Hole Cover

Courtesy of GENERAL MOTORS COMPANY

Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH 48027) , Fuel Pressure Relief (Without CH 48027) .
Remove the rear compartment liner. Refer to Rear Compartment Trim Panel Replacement .
Remove the fuel sender access hole cover bolts.
Remove the fuel sender access hole cover.

Fig 2: Identifying Fuel Feed Pipe & Harness Connectors

Courtesy of GENERAL MOTORS COMPANY

Disconnect the fuel feed rear pipe quick connect fitting (3) from the sender. Refer to Plastic Collar Quick Connect Fitting Service .
Disconnect the fuel level sensor wiring harness electrical connectors (1, 2) from the pressure sensor and sender.
Reposition the fuel feed pipe and harness connectors out of the way.

Fig 3: Attaching J 45722 To Lock Ring

Courtesy of GENERAL MOTORS COMPANY

Install the J 45722 to the lock ring.

Fig 4: Identifying Lock Ring

Courtesy of GENERAL MOTORS COMPANY

CAUTION:

Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

CAUTION:

Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

NOTE:

The fuel sender assembly may spring up from its position.
When removing the 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 the fuel sender assembly O-ring seal and replace it with a new one.
Carefully discard the fuel in the reservoir bucket into an approved container.

NOTE:

Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Rotate the lock ring in a counterclockwise direction.

Fig 5: Identifying Lock Ring, Fuel Sender Assembly & Fuel Pump Module O-Ring Seal

Courtesy of GENERAL MOTORS COMPANY

NOTE:

When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

Remove the lock ring (1) and the fuel sender assembly (2).
Slowly raise the module until the fuel level sensor float arm is just visible.
Tilt the fuel sender so that the float arm can clear the tank opening.
Carefully discard the fuel in the module reservoir bucket into an approved fuel container.

NOTE:

DO NOT reuse the old fuel pump module seal.

Remove and discard the fuel pump module O-ring seal (3).

Fig 6: Checking Lock Ring For Flatness

Courtesy of GENERAL MOTORS COMPANY

NOTE:

Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.
Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
Check the lock ring for flatness.

Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gauge at 7 different points.
If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.