Fuel Pump: Service and Repair

REMOVAL PROCEDURE

NOTICE: Do Not handle the fuel sender assembly by the fuel pipes. Due to the length of the fuel pipes, the amount of leverage generated by handling the fuel pipes could damage the joints.

NOTICE: In order to avoid damage to the fuel sender assembly, always replace the fuel sender O-rings when re-installing the fuel sender assembly.


1. Relieve the fuel system fuel pressure.
2. Drain the fuel tank to no more than 1/4 of a tank full.
3. Remove the spare tire cover, ,jack, and the spare tire.
4. Pull back the trunk liner.

Important: For rear compartment (trunk) accessible fuel sender assemblies, completely remove the rear compartment carpet before removing the fuel sender access panel.

5. Remove the fuel sender access panel (1).
6. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
7. Remove the quick-connect fittings at the fuel sender assembly.
6. Remove the electrical connector at the fuel sender.

IMPORTANT: When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The fuel sender assembly must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the fuel sender assembly is removed from the tank.

9. Remove the fuel sender retaining ring using the J 39675 Fuel Sender Spanner Wrench or equivalent.
10. Remove the fuel sender assembly retaining cam, using the J 39675 Fuel Sender Spanner Wrench or equivalent.
11. Remove the fuel sender assembly and the O-ring from the fuel tank.
12. Discard the fuel sender assembly O-ring.
13. Clean the fuel sender assembly O-ring sealing surfaces.
14. Inspect the fuel sender assembly O-ring sealing surfaces.

INSTALLATION PROCEDURE

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application.

General Motors will call out those fasteners that require a replacement after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant.

UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener.

When you install fasteners, use the correct tightening sequence and specifications.

Following these instructions can help you avoid damage to parts and systems.


1. Position the new fuel sender assembly O-ring on the fuel tank.
2. Assemble the fuel sender assembly and the fuel sender assembly retainer cam using the J 39675 Fuel Sender Spanner Wrench or equivalent.






IMPORTANT: Care should be taken not to fold over or twist the fuel pump strainer (1) when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

3. Install the fuel sender assembly and the fuel sender assembly retainer cam using the J 39765 Fuel Sender Spanner Wrench or equivalent.
4. Install the quick-connect fittings at the fuel sender assembly. Refer to Servicing Quick Connect Fillings.
5. Install the negative battery cable.
6. Inspect for leaks.
- Turn the ignition switch to the On position for 2 seconds.
- Turn the ignition switch to the Off for 10 seconds.
- Turn the ignition switch to the On position.
- Check for fuel leaks.
7. Install the fuel sender access panel.
8. Reposition the trunk liner.
9. Install the spare tire. the jack and the spare tire cover.
10. Add fuel and install the fuel tank filler pipe cap.

LEGEND IMAGE (2)
1. Fuel Sender Assembly
2. Fuel Level Sensor Assembly
3. Filter
4. Fuel Pump