GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Tank Assembly

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REMOVAL & INSTALLATION



1982-91 Vehicles

See Figure 1

  1. Disconnect the negative cable at the battery.
  2.  
  3. Raise and safely support the vehicles.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: View of the fuel tank mounting - 1991 vehicle shown

  1. Drain the tank. There is no drain plug, so drain as follows:
    1. If available, use a hand-operated pump device to drain as much fuel through the filler tube as possible.
    2.  
    3. If a hand-operated pump cannot be used or to complete the draining process, the remaining fuel in the tank must be siphoned through the main (not return) fuel feed line (the line to the fuel pump), because of the restrictor in the filler neck.
    4.  

  2.  
  3. Detach the tank meter assembly harness connector form the body harness connector.
  4.  
  5. If used, remove the ground wire retaining screw from the underbody.
  6.  
  7. Disconnect the hoses from the tank meter assembly and the hoses at the tank from the filler and vent pipes.
  8.  
  9. If necessary, unplug the level sending unit electrical connector.
  10.  
  11. Support the tank, then unfasten the two tank support straps and lower and remove the tank. Installation is the reverse of removal.
  12.  
  13. Using tool J 24187 or equivalent, remove the fuel tank meter assembly and seal/gasket. Remove the sound insulators.
  14.  
  15. Installation is the reverse of the removal procedure.
  16.  

1992-94 Vehicles

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the fuel tank by using a hand-operated pump device to drain as much fuel through the filler tube as possible.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: View of fuel tank mounting - 1992-94 vehicles

  1. Raise and safely support the vehicle.
  2.  
  3. Detach the fuel sender electrical connector.
  4.  
  5. Unfasten the muffler hanger bolts.
  6.  
  7. Remove the exhaust rubber hangers, then allow the exhaust system to rest on the rear axle.
  8.  
  9. Disconnect the hoses from the fuel tank sender. Grasp the filter and one nylon fuel connection line fitting. Twist the quick-connect fitting 1 / 4 turn in each direction to loosen any dirt within the fitting. Repeat for the other fitting. Using compressed air, blow out the dirt from the quick-connect fittings at the end of the fuel filter.
  10.  
  11. Detach the quick-connect fittings by pulling the release tabs back on the fuel line quick connector and pulling apart. If difficulty is encountered, tool J 38778 or equivalent can be used to separate the fitting.
  12.  
  13. Disconnect the hoses at the tank from the filler, vent and vapor pipes.
  14.  
  15. With the help of an assistant, support the fuel tank, then disconnect the two tank retaining straps and lower the tank from the vehicle.
  16.  
  17. Remove the sound insulators.
  18.  
  19. Remove the modular fuel sender, as outlined later in this section.
  20.  
  21. Inspect all connectors for dirt and burrs. Clean or replace, as required. Inspect the fuel line O-rings for cuts, nicks, swelling and/or distortion and replace as necessary.
  22.  

To install:
  1. Install the fuel sender assembly to the tank, as outlined later in this section.
  2.  
  3. Install the sound insulators.
  4.  
  5. With the help of an assistant, raise the fuel tank to the vehicle, then fasten the retaining straps. Tighten the retaining bolts to 24 ft. lbs. (33 Nm).
  6.  
  7. Connect the hoses to the filler, vent and vapor pipes.
  8.  
  9. Attach the nylon fuel feed and return connecting line quick-connect fittings to the fuel sender, as follows:
    1. Apply a few drops of clean engine oil to the male connector tube ends.
    2.  
    3. Push the connectors together to cause the retaining tabs/fingers to snap into place.
    4.  
    5. Once installed, pull on both ends of each connection to be sure they are secure.
    6.  

  10.  
  11. Install the exhaust rubber hangers.
  12.  
  13. Install the muffler hanger bolts, then tighten to 11 ft. lbs. (15 Nm).
  14.  
  15. Attach the fuel tank sender electrical connector.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Refill the fuel tank, then connect the negative battery cable.
  20.  
  21. Turn the ignition to the ON position for two seconds, then turn it to the OFF position for ten seconds. Turn again to the ON position and check for fuel leaks.
  22.  

MODULAR FUEL SENDER ASSEMBLY REPLACEMENT



See Figure 3

Always replace fuel sender assembly O-ring when reinstalling the fuel sender assembly

  1. Properly relieve fuel system pressure.
  2.  
  3. If not done already, disconnect the negative battery cable.
  4.  
  5. Drain fuel from the fuel tank assembly, as outlined in the fuel tank removal procedure.
  6.  
  7. Remove the fuel tank, as outlined earlier in this section.
  8.  


CAUTION
The modular fuel sender assembly may spring up from its position.

  1. While holding down the modular fuel sender assembly down, remove the snap ring from the designated slots in the retainer.
  2.  

When removing the fuel sender 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. Carefully discard the reservoir fuel into an approved container.

  1. Remove and discard the fuel sender O-ring.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: The module fuel sender assembly is mounted in the fuel tank

To install:
  1. Install a new O-ring on fuel sender-to-tank assembly.
  2.  
  3. Align tab on front of sender with the slot on front of the retainer snapring.
  4.  
  5. Slowly apply pressure to the top of the spring loaded sender, until it aligns flush with retainer on tank assembly.
  6.  
  7. Insert the snapring into the designated slots. Be sure that the snapring is fully seated in the retainer.
  8.  
  9. Install fuel tank, the carefully lower the vehicle and refill the gas tank.
  10.  
  11. Connect the negative battery cable, then turn the ignition to the ON position for two seconds, then turn it to the OFF position for ten seconds. Turn again to the ON position and check for fuel leaks.
  12.  

 
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