GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • EN-48278 Fuel Tank Sender Wrench
    • CH-48482 Fuel Tank Sender Wrench

Removal Procedure Up to 24th Aug 07

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

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

  2. Object Number: 1949849  Size: SH
  3. Disconnect the secondary fuel tank module electrical connector (1).

  4. Object Number: 2132714  Size: SH
  5. Rotate the cam lock ring (2) counter-clockwise using EN-48278  (1).
  6. Important: The cam lock ring (2) is a single use part and therefore must be discarded after removal.

  7. Remove the cam lock ring (2) from the fuel tank.

  8. Object Number: 1949851  Size: SH

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

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

  10. Object Number: 1949854  Size: SH
  11. Remove the fuel supply tube (1). Refer to Plastic Collar Quick Connect Fitting Service.
  12. Remove the secondary fuel tank module (2) from the fuel tank.

  13. Object Number: 1949847  Size: SH
  14. Remove the secondary fuel tank module seal (1) from the fuel tank.
  15. Do not reuse the seal.

Installation Procedure Up to 24th Aug 07


    Object Number: 1949847  Size: SH
  1. Place the new secondary fuel tank module seal (1) in the locating groove on the fuel tank.

  2. Object Number: 1949854  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: Make sure 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. Object Number: 2132714  Size: SH
  8. Install a NEW cam lock ring (2) to the fuel tank.
  9. Rotate the cam lock ring (2) clockwise using the EN-48278  (1) until fully seated.

  10. Object Number: 1949849  Size: SH
  11. Connect the secondary fuel tank module electrical connector (1).
  12. Install the fuel tank. Refer to Fuel Tank Replacement.

Removal Procedure From 25th Aug 07

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

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

  2. Object Number: 2132720  Size: SH
  3. Disconnect the secondary fuel tank module electrical connector (1).

  4. Object Number: 2132721  Size: SH
  5. Rotate the cam lock ring (2) counter-clockwise using the CH-48482  (1).
  6. Important: The cam lock ring (1) is a single use part and therefore must be discarded after removal.

  7. Remove the cam lock ring (2) from the fuel tank.

  8. Object Number: 1949851  Size: SH

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

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

  10. Object Number: 1949854  Size: SH
  11. Remove the fuel supply tube (1). Refer to Plastic Collar Quick Connect Fitting Service.
  12. Remove the secondary fuel tank module (2) from the fuel tank.

  13. Object Number: 1949847  Size: SH
  14. Remove the secondary fuel tank module seal (1) from the fuel tank.
  15. Do not reuse the seal.

Installation Procedure From 25th Aug 07


    Object Number: 1949847  Size: SH
  1. Place the new secondary fuel tank module seal (1) in the locating groove on the fuel tank.

  2. Object Number: 1949854  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: Make sure 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. Object Number: 2132721  Size: SH
  8. Install a NEW cam lock ring (2) to the fuel tank (3).
  9. Rotate the cam lock ring (2) clockwise using the CH-48482  (1) until fully seated.

  10. Object Number: 2132720  Size: SH
  11. Connect the secondary fuel tank module electrical connector (1).
  12. Install the fuel tank. Refer to Fuel Tank Replacement.