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Fuel Sender Assembly: Installation

WARNING: This page is about a different car, the 2002 Chevrolet Prizm. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes.
  1. Position the new fuel sender assembly "O" ring on the fuel sender assembly. Install the fuel sender assembly into the fuel tank. Install the hold down plate for the fuel sender assembly. Secure the hold down plate for the fuel sender assembly with the 8 bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  2. Install the fuel pipe to the fuel sender fitting. Secure the fuel pipe with the retaining clip. Connect the electrical connector to the fuel sender assembly. Connect the negative battery cable. Pressurize the fuel system and check for leaks. Inspect the butyl caulk seal for the fuel sender access panel.
  3. Replace any missing butyl caulk as necessary. Install the access panel to the rear seat floor. Relocate the carpet under the seat and the left sill plate area. Install the sill plate to the left side door opening. Install the rear seat bottom cushion.
Fig 1: Identifying Fuel Sender Assembly Components
G00112802Courtesy of GENERAL MOTORS CORP.
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