GM Service Manual Online
For 1990-2009 cars only

Tools Required

J 45747 Fuel Tank Sender Wrench

Removal Procedure

    Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

  1. Remove the fuel tank. Refer to Fuel Tank Replacement .

  2. Object Number: 820617  Size: SH
  3. Remove the fuel tank hoses. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Disconnect the electrical connector from the primary fuel tank module.

  5. Object Number: 820618  Size: SH

    Important: Do not allow the tool to come in contact with the fuel pipes while unlocking the cam lock ring.

  6. Rotate the cam lock ring counter-clockwise using the J 45747 .
  7. Remove the cam lock ring from the fuel tank.

  8. Object Number: 820619  Size: SH

    Important: The primary fuel tank module (1) is horizontal in the installed position, but pivots vertically for removal.

  9. Carefully lift the primary fuel tank module (1) from the fuel tank only enough to access the transfer tube (2).

  10. Object Number: 820621  Size: SH
  11. Complete the following in order to disconnect the transfer tube from the primary fuel tank module:
  12. 7.1. Pull the locking mechanism away from the module.
    7.2. Remove the transfer tube from the module.

    Object Number: 820623  Size: SH
  13. Remove the primary fuel tank module from the fuel tank.
  14. Remove the primary fuel tank module seal from the module.
  15. Do not reuse the seal.

Installation Procedure


    Object Number: 820624  Size: SH

    Important: Ensure the seal bead is facing the fuel tank.

  1. Place the new primary fuel tank module seal (1) over the module (2).

  2. Object Number: 820619  Size: SH
  3. Complete the following in order to connect the transfer tube (2) to the primary fuel tank module (1).
  4. 2.1. Grasp the transfer tube (2) from inside the fuel tank.
    2.2. Position the module (1) near the module opening.
    2.3. Connect the transfer tube (2) to the module (1).

    Important: 

       • The primary fuel tank module (1) is horizontal in the installed position, but pivots from the vertical position for installation.
       • Ensure the fuel level float is free from binding while inserting the module (1).

  5. Carefully insert the primary fuel tank module (1) into the fuel tank.
  6. Press the primary fuel tank module (1) downward, aligning the module to the encapsulated ring.
  7. Position the cam lock ring to the fuel tank.

  8. Object Number: 820618  Size: SH

    Important: Do not allow the tool to come in contact with the fuel pipes while locking the cam lock ring.

  9. Rotate the cam lock ring clockwise using the J 45747 until fully seated.

  10. Object Number: 820617  Size: SH
  11. Connect the electrical connector to the primary fuel tank module.
  12. Install the fuel tank hoses. Refer to Plastic Collar Quick Connect Fitting Service .
  13. Install the fuel tank. Refer to Fuel Tank Replacement .