GM Service Manual Online
For 1990-2009 cars only

Fuel Tanks

Tools Required

    • J 34730-1A Fuel Pressure Gauge
    • J 37088-A Tool Set, Fuel Line Quick Connect Separator

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  3. Drain the fuel tanks. Refer to Fuel Tank Draining .
  4. Remove the fuel tanks. Refer to Fuel Tank Replacement .
  5. Remove the fuel sender assemblies. Refer to Fuel Sender Assembly Replacement .
  6. Inspect the left fuel sender strainer. Replace a contaminated strainer (left fuel sender only) and inspect the fuel pump.
  7. Inspect the left fuel sender fuel pump inlet for dirt and debris. Replace the left fuel sender assembly if you find dirt or debris in the fuel pump inlet.
  8. Inspect the right fuel sender strainers. Replace the right fuel sender assembly if you find a contaminated strainer(s). The right fuel sender strainers are not serviced separately.
  9. Important: When flushing the fuel tanks, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations.

  10. Flush the fuel tanks with hot water.
  11. Pour the water out of the fuel sender assembly openings. Rock the tanks to be sure that removal of the water from the tanks is complete.
  12. Install the fuel sender assemblies. Refer to Fuel Sender Assembly Replacement .
  13. Install the fuel tanks. Refer to Fuel Tank Replacement .
  14. Refill the fuel system.
  15. Install the fuel filler cap.
  16. Connect the negative battery cable.
  17. Inspect for leaks.
  18. 16.1. Turn the ignition switch ON for 2 seconds.
    16.2. Turn the ignition switch OFF for 10 seconds.
    16.3. Turn the ignition switch ON.
    16.4. Check for fuel leaks.
  19. Program the transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.
  20. Perform the idle learn procedure. Refer to PCM Idle Learn Procedure .