GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Tank Assembly

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REMOVAL & INSTALLATION




CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

1988 Vehicles

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Fuel tank mounting components



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Fig. Fig. 2: Fuel tank insulator mounting positions

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure, as outlined earlier in this section.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Use a suitable hand operated pump device to drain the fuel through the filler tube into an approved container.
  8.  


CAUTION
Observe all applicable safety precautions when working around gasoline. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.

  1. Support the fuel tank with a suitable jack.
  2.  
  3. Remove the 2 bolts securing the fuel tank straps, then swing the straps out of the way.
  4.  
  5. Lower the fuel tank enough to disconnect the vapor hose from the fuel sender assembly and the vapor hose from the vapor pipe at the rear of the fuel tank.
  6.  
  7. Detach the electrical connector from the fuel sender assembly and remove the two retaining clips. If equipped, disconnect the ground strap.
  8.  
  9. Disconnect the fuel filler and vent hoses from the fuel tank.
  10.  
  11. Remove the tank from the vehicle, slowly to ensure all connections and hoses have been disconnected.
  12.  

To install:
  1. Clean all parts well. Inspect the tank for dents, rust or other damage. On high-mileage vehicles, it may be good practice to remove the fuel pump module and replace the flexible strainer on the fuel pump.
  2.  
  3. Position the fuel tank under the vehicle and raise the tank with a suitable jack.
  4.  
  5. Connect the fuel feed and return lines to the sender assembly.
  6.  
  7. Attach the electrical connector to the fuel sender assembly. If equipped, connect the ground strap.
  8.  
  9. Raise the tank into position into the vehicle and swing the mounting straps under the tank.
  10.  
  11. Install the front fuel tank strap mounting bolts and tighten to 35 ft. lbs. (47 Nm).
  12.  
  13. Remove the jack.
  14.  
  15. Connect the fuel filler and vent hoses to the tank.
  16.  
  17. Carefully lower the vehicle, then refill the fuel system
  18.  
  19. Connect the negative battery cable, then install the fuel filler cap, if not done already.
  20.  
  21. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  22.  

1989-94 Vehicles

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure, as outlined earlier in this section.
  4.  
  5. Raise and safely support the vehicle.
  6.  


CAUTION
Observe all applicable safety precautions when working around gasoline. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.

  1. Use a suitable hand operated pump device to drain the fuel through the filler tube into an approved container.
  2.  

Before disconnecting any fuel lines from the fuel tank, thoroughly clean around all hose connections.

  1. Disconnect the fuel filler vent hose from the fuel tank.
  2.  
  3. Detach the fuel filler hose from the fuel filler inlet tube on the fuel tank. Position the hose out of the way.
  4.  
  5. Disconnect the vapor hose from the front of the fuel tank.
  6.  
  7. Detach the fuel return pipe and position the hose out of the way.
  8.  
  9. Disconnect the two rear rubber exhaust hangers from the rear of the exhaust system and allow the exhaust system to hang down slightly.
  10.  
  11. Unfasten the exhaust shield mounting bolts, then remove the exhaust shield.
  12.  
  13. Support the fuel tank with a suitable jack.
  14.  
  15. Remove the two bolts securing the fuel tank straps, then swing the straps out of the way.
  16.  
  17. Lower the fuel tank enough to disconnect the vapor hose from the fuel sender assembly and the vapor hose from the vapor pipe at the rear of the fuel tank.
  18.  
  19. Detach the electrical connector from the fuel sender assembly and remove the two retaining clips.
  20.  
  21. Remove the tank from the vehicle, slowly to ensure all connections and hoses have been disconnected.
  22.  

To install:
  1. Clean all parts well. Inspect the tank for dents, rust or other damage. On high-mileage vehicles, it may be good practice to remove the fuel pump module and replace the flexible strainer on the fuel pump.
  2.  
  3. Position the fuel tank under the vehicle and raise the tank with a suitable jack.
  4.  
  5. Connect the vapor hose to the fuel tank at the vapor pipe at the rear of the tank and connect the vapor hose to the sender assembly.
  6.  
  7. Attach the electrical connector to the fuel sender assembly.
  8.  
  9. Connect the fuel feed and return lines to the sender assembly.
  10.  
  11. Raise the tank into position into the vehicle and swing the mounting straps under the tank.
  12.  
  13. Install the front fuel tank strap mounting bolts and tighten to 35 ft. lbs. (47 Nm).
  14.  
  15. Remove the jack.
  16.  
  17. Connect the fuel return pipe to the fuel feed pipe.
  18.  
  19. Attach the rear fuel feed pipe to the inlet side of the fuel filter.
  20.  
  21. Tighten the line fittings to 16 ft. lbs. (22 Nm). Make sure to use a back-up wrench to prevent the fuel filter from turning.
  22.  
  23. Connect the vapor hose to the vapor pipe at the front of the vehicle.
  24.  
  25. Attach the fuel filler vent hose to the tank. Connect the fuel filler hose to the fuel filler neck of the tank.
  26.  
  27. Install the exhaust heat shield and the mounting bolts.
  28.  
  29. Position the exhaust system and install the rubber hangers.
  30.  
  31. Carefully lower the vehicle, then refill the fuel system
  32.  
  33. Connect the negative battery cable, then install the fuel filler cap, if not done already.
  34.  
  35. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  36.  

1995-96 Vehicles

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Raise and safely support the vehicle.
  6.  


CAUTION
Observe all applicable safety precautions when working around gasoline. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.

  1. Drain the fuel tank using the following procedure:
    1. Make sure the negative battery cable has been disconnected.
    2.  

  2.  

Do NOT attempt to drain fuel through the filler neck, or damage to the filler neck check-ball may occur.

  1. Disconnect the fuel tank filler neck from the filler neck hose.
  2.  
  3. Detach the quick-connecting fittings at the fuel tank.
  4.  
  5. Remove the EVAP hose from the connection at the front of the tank.
  6.  
  7. Disconnect the two rear rubber exhaust hangers from the rear of the exhaust system and allow the exhaust system to hang down slightly.
  8.  
  9. Unfasten the exhaust pipe heat shield bolts and remove the shield.
  10.  
  11. With the help of an assistant, support the tank and remove the fuel tank straps with attaching bolts retaining the fuel tank straps.
  12.  

Do not bend the fuel tank straps, as this may damage the straps.

  1. Lower the fuel tank enough to disconnect the fuel sender electrical connector and remove the retaining clips.
  2.  
  3. Remove the EVAP hose from the sender assembly.
  4.  
  5. Remove the EVAP hose from the EVAP pipe at the rear of the fuel tank.
  6.  
  7. Remove the tank from the vehicle slowly to ensure all connections and hoses have been disconnected. Place the tank in a suitable work area.
  8.  

To install:
  1. Clean all parts well. Inspect the tank for dents, rust or other damage. On high-mileage vehicles, it may be good practice to remove the fuel pump module and replace the flexible strainer on the fuel pump.
  2.  
  3. With the help of an assistant, position and support the fuel tank. Position the fuel tank straps, loosely install the fuel tank strap attaching bolts and connect the following:
    1. EVAP hose to the vapor pipe at the rear of the tank.
    2.  
    3. EVAP hose to the fuel sender assembly.
    4.  
    5. Fuel sender electrical connector and install the retainer clips.
    6.  
    7. Rear fuel tank strap attaching bolts. Tighten all retainer bolts to 35 ft. lbs. (47 Nm).
    8.  

  4.  


CAUTION
To reduce the risk of fire and personal injury, always apply a few drops of clean engine oil to the quick-connect male tube ends. This will ensure proper connection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connection will swell and may prevent proper connection if not lubricated.

  1. Attach the quick-connect fittings.
  2.  
  3. Connect the EVAP hose to the EVAP pipe at the front of the tank.
  4.  
  5. Install the fuel filler hose to the fuel tank.
  6.  
  7. Install the heat shield and secure with the retaining screws.
  8.  
  9. Install the rubber pipe hangers.
  10.  
  11. Carefully lower the vehicle, then refill the fuel system
  12.  
  13. Connect the negative battery cable, then install the fuel filler cap, if not done already.
  14.  
  15. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  16.  

SENDING UNIT REPLACEMENT



1988-90 Vehicles
  1. Properly relieve the fuel system pressure, as outlined earlier in this section.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle with jackstands.
  6.  
  7. Safely drain, then remove the fuel tank assembly as outlined later in this section.
  8.  
  9. Turn the fuel pump cam lockring counterclockwise and lift the assembly out of the tank.
  10.  

To install:
  1. Replace any attaching hoses or rubber sound insulator that show signs of deterioration.
  2.  
  3. Install the pump/sender assembly into the tank. Always use a new O-ring seal.
  4.  

Be careful not to fold over or twist the strainer when installing the sensor unit. Also, make sure the strainer does not block full travel of the float arm.

  1. Install the cam lockring and turn clockwise to lock.
  2.  
  3. Install the fuel tank as outlined in this section.
  4.  
  5. Carefully lower the vehicle, then connect the negative battery cable.
  6.  
  7. Fill the tank with four gallons of gas and check for fuel leaks.
  8.  

1991-96 Vehicles

See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the fuel sending unit related components

  1. Properly relieve the fuel system pressure, as outlined earlier in this section.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle with jackstands.
  6.  
  7. Safely drain, then remove the fuel tank assembly as outlined in this section.
  8.  

Clean all fuel pipe and hose connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.

  1. For 1991 vehicles, disconnect the rear fuel feed and return pipe assemblies from the fuel level meter.
  2.  
  3. For 1992-96 vehicles, disconnect the chassis-to-sender fuel feed and return pipes as follows:
    1. turn in each direction to loosen any dirt within the quick-connect fitting. Repeat for the other fitting
    2.  

  4.  


CAUTION
Safely glasses MUST be worn when using compressed air, as flying dirt particles may cause eye injury.

  1. Using tool J 35731 or equivalent, remove the fuel level meter assembly retaining cam, fuel level meter assembly and the O-ring from the fuel tank. Discard the fuel level meter O-ring and the fuel feed and return tube O-rings.
  2.  

To install:
  1. Place a new fuel sender assembly O-ring on the fuel tank.
  2.  

Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, make sure the fuel pump strainer does not block full travel of the float arm.

  1. Install the fuel sender assembly and the fuel sender assembly retainer cam using tool J 35731.
  2.  
  3. For 1992-96 vehicles connect the fuel feed and return pipes, as follows:
    1. Apply a few drops of clean engine oil to the male 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 make sure they are secure.
    6.  
    7. Repeat for the other fitting.
    8.  

  4.  
  5. For 1991 vehicles, position new O-rings on the fuel level meter fuel feed and return tubes. Attach the rear fuel feed and return pipe assemblies to the fuel level meter. Tighten the fittings to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the fuel tank as outlined in this section.
  8.  
  9. Carefully lower the vehicle, then connect the negative battery cable.
  10.  
  11. Fill the tank with about four gallons of gas and check for fuel leaks. Turn the ignition switch to the ON position for 2 seconds, then turn OFF for 10 seconds. Again, turn the ignition to the ON position, and check for fuel leaks.
  12.  

 
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