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Home >> Chevrolet >> 2006 >> Malibu SS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 3.9L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Module Replacement >> Installation Procedure
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Installation Procedure

Fig 1: Identifying Fuel Sender Assembly
GM1580739Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW O-ring seal (3) onto the fuel sender.
  2. Install the fuel sender assembly (2) into the fuel tank far enough to connect the vapor line quick connect fitting on the underside of the sender cover.
    Fig 2: View Of Fuel Sender Assembly
    GM1580735Courtesy of GENERAL MOTORS CORP.
  3. Connect the vapor line quick connect fitting (1). Refer to QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) .
  4. Align the cover "paddle" or anti-rotation feature with the corresponding feature in the top of the fuel tank.
  5. Slowly apply pressure to the top of the spring loaded sender cover until the sender aligns flush with the surface of the tank.
    Fig 3: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Some lock rings 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.
    IMPORTANT: 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.
  6. Use the J 45722  in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
  7. Turn the lock ring until the ring seats on the second detent.
    Fig 4: View Of Evaporative Emission (EVAP) Vapor Line Quick Connect Fittings
    GM1580734Courtesy of GENERAL MOTORS CORP.
  8. Engage the fuel feed line to the retaining features built into the fuel tank.
  9. Connect the EVAP vapor line quick connect fittings (1, 2). Refer to QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) .
  10. Connect the fuel pressure sensor and sender electrical connections.
  11. Install the fuel tank. Refer to FUEL TANK REPLACEMENT .
  12. Lower the vehicle.
  13. Refill the tank.
  14. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  15. Inspect for fuel leaks through the following steps:
    1. Turn the ignition to the ON position for 2 seconds
    2. Turn the ignition to the OFF position for 10 seconds.
    3. Turn the ignition to the ON position
    4. Check for fuel leaks.
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