GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Tools Required

    • J 34730 Fuel Pressure Gauge
    • J 35731 Fuel Sender Spanner Wrench

    Object Number: 180378  Size: SH
  1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief .

  2. Object Number: 20975  Size: SH
  3. Drain the fuel tank (1). Refer to Fuel Tank Draining .

  4. Object Number: 21195  Size: SH
  5. Remove the fuel tank (2). Refer to Fuel Tank Replacement .

  6. Object Number: 180726  Size: SH
  7. Remove the fuel sender assembly from the fuel tank (1). Refer to Fuel Sender Assembly Replacement .

Disassemble Procedure


    Object Number: 181805  Size: SH
  1. Inspect the position of the fuel pump fuel strainer (2) for installation.
  2. Support the fuel pump (1) with one hand and grasp the fuel pump fuel strainer with the other hand
  3. Pull the fuel pump fuel strainer off of the fuel pump.
  4. Inspect the fuel pump fuel strainer. If the fuel pump fuel strainer is contaminated, the fuel tank should be cleaned.
  5. Discard the fuel pump fuel strainer after inspection.
  6. Inspect the fuel pump inlet for dirt and debris. If dirt and debris are found, the fuel pump should be replaced.

  7. Object Number: 181794  Size: SH
  8. Remove the fuel pump electrical connector, if fuel pump is being replaced.
  9. Place the fuel sender assembly upside down on a bench.
  10. Notice: In order to prevent damage to the fuel pump, Do Not run the fuel pump unless the fuel pump is submerged in fuel.

  11. Pull the fuel pump (1) downward in order to remove the fuel pump from the fuel pump mounting bracket, then tilt the fuel pump outward and remove the fuel pump from the fuel feed pipe.
  12. Transfer the fuel pump (1) to the new fuel sender (4), if fuel sender is being replaced.

Assemble Procedure


    Object Number: 180726  Size: SH
  1. Install the rubber insulator on the fuel pump.
  2. Position the fuel sender assembly upside down.
  3. Important: Always install a new fuel pump fuel strainer when installing a fuel pump.

  4. Install the fuel pump (1) between the fuel feed pipe and the fuel pump mounting bracket.
  5. Install the fuel pump electrical connector.
  6. Position the new fuel pump fuel strainer (2) on the fuel pump and push on the outer edge of the fuel pump fuel strainer until the fuel pump fuel strainer is fully seated.

Installation Procedure

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.


    Object Number: 180726  Size: SH
  1. Install the fuel sender assembly into the fuel tank (1). Refer to Fuel Sender Assembly Replacement .

  2. Object Number: 32726  Size: SH
  3. Install the fuel tank. Refer to Fuel Tank Replacement .

  4. Object Number: 180188  Size: SH
  5. Lower the vehicle.
  6. Add fuel and install the fuel tank filler pipe cap.
  7. Install the negative battery cable. Refer to Battery Cable .
  8. Inspect for leaks.
  9. 6.1. Turn the ignition switch to the On position for 2 seconds.
    6.2. Turn the ignition switch to the Off for 10 seconds.
    6.3. Turn the ignition switch to the On position.
    6.4. Check for fuel leaks.