Removal & Installation (Cavalier & Sunfire - 2.2L & 2.4L)
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
CAUTION:
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
NOTE:
The modular fuel sender assembly may spring up from its position. When removing the modular assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. Tip the modular assembly slightly during removal to avoid damage to the float. Use a shop towel to absorb any leakage.
- Disconnect the negative battery cable. Relieve the fuel system pressure. See FUEL PRESSURE RELIEF . Drain the fuel tank.
- Raise and support the vehicle. Grasp the nylon fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for the other nylon fuel pipe quick-connect fitting. Using compressed air, blow out dirt from the quick-connect fittings at end of the fuel pipes. Disconnect the quick-connect fittings at the fuel tank.
- Disconnect the quick-connect fitting at the fuel filter. Remove the quick connect fittings at the end of the fuel pipe and vapor pipes. Remove the muffler support bolts. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear suspension. Remove the exhaust heat shield. Remove the hoses at the fuel tank from the filler, vent and vapor pipes.
- With the aid of an assistant, support fuel tank and disconnect the 2 fuel tank retaining straps. With the aid of an assistant, lower the fuel tank. Remove the fuel tank pressure sensor electrical connector. Remove the fuel sender electrical connector. Remove the tank from the vehicle. See Fig 1.
- While holding the modular fuel sender assembly (3) down, remove the snap ring (1) from designated slots located on the retainer (2).
- Install a NEW "O" ring on the modular fuel sender. Install the modular fuel sender to the fuel tank. Align the tab on front of the modular fuel sender with slot on front of the retainer snap ring. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.
- Insert the snap ring into the designated slots. Install the fuel tank. Lower the vehicle. Refill the fuel tank. Connect the negative battery cable.
- Inspect for fuel leaks through the following steps. Turn the ignition switch to the ON position for two seconds. Turn the ignition switch to the OFF position for ten seconds. Turn the ignition switch to the ON position Check for fuel leaks.
CAUTION:
Be sure that the snap ring is fully seated within the tab slots.