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: 820625  Size: SH
  3. Disconnect the electrical connector from the secondary fuel tank module.

  4. Object Number: 820626  Size: SH
  5. Rotate the cam lock ring counter-clockwise using the J 45747 .
  6. Remove the cam lock ring from the fuel tank.

  7. Object Number: 820620  Size: SH
  8. Carefully lift the secondary fuel tank module (2) from the fuel tank only enough to access the transfer tube (1).

  9. Object Number: 820621  Size: SH
  10. Complete the following in order to disconnect the transfer tube from the secondary fuel tank module.
  11. 6.1. Pull the locking mechanism away from the module.
    6.2. Remove the transfer tube from the module.

    Object Number: 820627  Size: SH
  12. Remove the secondary fuel tank module from the fuel tank.
  13. Remove the secondary fuel tank module seal from the module.
  14. 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 secondary fuel tank module seal (1) over the module (2).

  2. Object Number: 820620  Size: SH
  3. Complete the following in order to connect the transfer tube (1) to the secondary fuel tank module (2).
  4. 2.1. Grasp the transfer tube (1) from inside the fuel tank.
    2.2. Position the module (2) near the module opening.
    2.3. Connect the transfer tube (1) to the module (2).

    Important: Ensure the fuel level float is free from binding while inserting the module (2).

  5. Carefully insert the secondary fuel tank module (2) into the fuel tank.
  6. Press the secondary fuel tank module (2) downward, aligning the module to the encapsulated ring.
  7. Position the cam lock ring to the fuel tank.

  8. Object Number: 820626  Size: SH
  9. Rotate the cam lock ring clockwise using the J 45747 until fully seated.

  10. Object Number: 820625  Size: SH
  11. Connect the electrical connector to the secondary fuel tank module.
  12. Install the fuel tank. Refer to Fuel Tank Replacement .