Removal Procedure

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.

Fig 1: View Of Evaporative Emission (EVAP) Vapor Line Quick Connect Fittings

Courtesy of GENERAL MOTORS CORP.

Remove the fuel tank. Refer to Fuel Tank Replacement .
Disconnect the fuel pressure sensor and sender electrical connections.
Disconnect the evaporative emission (EVAP) vapor line quick connect fittings (1, 2). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

Fig 2: Identifying Lock Ring

Courtesy of GENERAL MOTORS CORP.

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

NOTE: 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.

IMPORTANT: 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. See Special Tools .

Fig 3: View Of Fuel Sender Assembly

Courtesy of GENERAL MOTORS CORP.

IMPORTANT:

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 and replace it with a new one.
Carefully discard the fuel in the reservoir bucket into an approved container.

Raise the fuel sender assembly out of the tank far enough to access the vapor line quick connect fitting (1) on the underside of the sender cover.
Disconnect the vapor line quick connect fitting (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

Fig 4: Identifying Fuel Sender Assembly

Courtesy of GENERAL MOTORS CORP.

Remove the fuel sender assembly (2) from the fuel tank.

Fig 5: Checking Lock Ring For Flatness

Courtesy 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.

IMPORTANT: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

IMPORTANT: Check the lock ring for flatness.

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