Removal Procedure

WARNING: This page is about a different variant/trim than selected.

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.

Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
Relieve the system fuel pressure. Refer to Fuel Pressure Relief Procedure .
Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Remove the fuel tank. Refer to Fuel Tank Replacement (Malibu Sedan) .
Disconnect the electrical and ventilation connections on the modular fuel sender assembly cover.

IMPORTANT:

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. It must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one.
Carefully discard the fuel in the reservoir bucket into an approved container.

Fig 1: Raising Fuel Sender Assembly Out Of Tank (Malibu Sedan)

Courtesy of GENERAL MOTORS CORP.

While having an assistant hold the fuel tank, use J 45722 to turn the modular fuel sender assembly lock ring counter-clockwise until the ring is released from the fuel tank. See Special Tools .
Raise the fuel sender assembly out of the tank far enough to access the ventilation harness connection on the underside of the module cover.
Disconnect the ventilation harness quick connect before attempting to fully remove the modular fuel sender assembly.