Removal & Installation (Lumina) - 3.1L)

CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

CAUTION: The modular fuel sender assembly may spring up from its position. When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float. Discard the fuel sender "O" ring and replace the "O" ring with a NEW one.

CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

Relieve the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Drain the fuel tank.
Raise and support the vehicle. Remove the fuel tank filler EVAP hose from the fuel tank. Remove the fuel tank filler hose from the fuel tank. Disconnect the quick-connect fittings at the fuel tank.
Disconnect the modular fuel sender and the fuel tank pressure sensor electrical connectors. Remove the EVAP pipe from the connection at the front of the fuel tank. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly. Remove the exhaust pipe heat shield bolts and the exhaust pipe heat shield.
With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts. Lower the fuel tank enough in order to disconnect the fuel sender electrical connector and remove the fuel sender retaining clips. Disconnect the EVAP pipe to the rear of the fuel tank. Disconnect the EVAP pipe to the fuel sender assembly. Remove the fuel tank from the vehicle.
Carefully discard the reservoir fuel into an approved container. With the Fuel Sender Lock Nut Tool (J-39765), press down and rotate the cam lock ring until free of the fuel sender retaining tabs. Remove the modular fuel sender assembly. See Figure. Remove the fuel level sensor.

CAUTION: Be sure that the cam lock ring is fully seated within the tab slots.

Install the fuel level sensor.
To install, reverse removal procedure. Install the NEW "O" ring on the fuel tank. Align the fuel lines parallel with the mark on the fuel tank. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.
Connect the negative battery cable. Inspect for fuel leaks using the following procedure: Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.