MonteCarlo 2000

Fuel Pump

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Removal & Installation



Specific to:

Buick Century 1997-2000

Buick Regal 1997-2000

Chevrolet Lumina 1997-2000

Chevrolet Monte Carlo 1997-2000

Oldsmobile Cutlass Supreme 1997

Oldsmobile Intrigue 1998-2000

Pontiac Grand Prix 1997-2000

The fuel pump is located inside the fuel tank. It is part of a so-called 'fuel pump module' or 'fuel sender assembly' which includes the fuel pump, the fuel tank gauge sending unit, the fuel pump strainer and related components. These fuel pump module assemblies are expensive. Be sure of the diagnosis before attempting this procedure to replace a fuel pump.

On some vehicles covered by this manual, the fuel sender assembly can be accessed through a removable panel on the trunk floor. On others, the fuel tank must be removed. The spare tire and trunk carpet have to be removed to expose the trunk floor access panel to see which is the proper procedure to use on your vehicle.

With Trunk Access Panel

Specific to:

Buick Century 1997-2000

Buick Regal 1997-2000

Chevrolet Lumina 1997-2000

Chevrolet Monte Carlo 1997-2000

Oldsmobile Cutlass Supreme 1997

Oldsmobile Intrigue 1998-2000

Pontiac Grand Prix 1997-2000


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Wear safety glasses to protect the eyes from fuel splash.


NOTE
Always replace the fuel sender O-rings when reinstalling the fuel sender assembly. Note that the module assembly is spring loaded and it will spring-up when the retaining snapring is removed.


WARNING
When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The sender assembly must be tipped slightly during removal to avoid damage to the float. Place any remaining fuel into an approved container once the sender assembly is removed from the fuel tank.



Click image to see an enlarged view

Fig. Some vehicles have access panels built into the trunk floor so the fuel pump/sender module can be removed without having to remove the fuel tank

  1. Relieve the fuel system pressure using the procedures found in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the fuel tank to no more than 1 / 4 of a tank full.
  6.  
  7. Remove the spare tire cover, the jack and the spare tire.
  8.  
  9. Remove the trunk liner.
  10.  
  11. Remove the seven access panel retaining nuts, then lift off the panel.
  12.  
  13. Detach the fuel pump/sender electrical connector.
  14.  
  15. Clean the fuel pipes and the fuel sender assembly to prevent possible fuel contamination during removal.
  16.  
  17. Remove the quick-connect fittings at the fuel sender assembly. Information on servicing these fittings is found earlier in this section.
  18.  
  19. Remove the fuel sender assembly retaining snapring. Expect the sender to spring-up when the snapring is removed.
  20.  


CAUTION
Do not handle the fuel sender assembly by the fuel pipes. The pipe joints are very fragile. The amount of leverage generated by handling the fuel pipes could damage the joints.

  1. Carefully remove the sender assembly. Inspect and clean the O-ring sealing surfaces.
  2.  

To install:


NOTE
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 that the fuel pump strainer does not block the full travel of the fuel gauge float arm.

  1. Position the new fuel sender assembly O-ring on the tank and carefully install the sender assembly into the fuel tank.
  2.  
  3. Install the retaining snapring. Be sure the snapring is fully seated within the tab slots on the fuel tank.
  4.  
  5. Assemble the electrical connector to the sender assembly.
  6.  
  7. Install the quick-connect fittings to the sender assembly.
  8.  
  9. Connect the negative battery cable and install the fuel filler cap.
  10.  
  11. Inspect for leaks using the following procedure:
    1. Turn the ignition switch to the ON position for 2 seconds.
    2.  
    3. Turn the ignition switch to the ON position for 10 seconds.
    4.  
    5. Turn the ignition switch to the ON position again.
    6.  
    7. Check for fuel leaks.
    8.  

  12.  
  13. When satisfied with the fuel sender installation and that connections are secure, install the access cover and the retaining nuts. Snug down the nuts to 96 inch lbs. (10 Nm).
  14.  
  15. Install the trunk liner, spare tire, jack and tire cover.
  16.  

Without Trunk Access Panel

Specific to:

Buick Century 1997-2000

Buick Regal 1997-2000

Chevrolet Lumina 1997-2000

Chevrolet Monte Carlo 1997-2000

Oldsmobile Cutlass Supreme 1997

Oldsmobile Intrigue 1998-2000

Pontiac Grand Prix 1997-2000


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Wear safety glasses to protect the eyes from fuel splash.


NOTE
On Oldsmobile models, a special tool, J 35731 Fuel Sender Spanner Wrench is required to disengage the fuel sender assembly. On Chevrolet models, a snapring is usually used to retain the spring-loaded module assembly which will spring-up when the retaining snapring is removed. Always replace the fuel sender O-ring when reinstalling the fuel sender assembly.


WARNING
When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The sender assembly must be tipped slightly during removal to avoid damage to the float. Place any remaining fuel into an approved container once the sender assembly is removed from the fuel tank.



Click image to see an enlarged view

Fig. On applications with extra-long fuel pipes, the fuel tank has to be removed to service the fuel sender module

  1. Relieve the fuel system pressure using the procedures found in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the fuel tank into a suitable container.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the fuel tank using the procedures found in this section. As the tank is being lowered, clean the fuel pipes and the fuel sender assembly to prevent possible fuel contamination. Remove the quick-connect fittings at the fuel sender assembly. Information on servicing these fittings is found in the section. Detach the electrical connector and with an assistant, lower the fuel tank to the floor.
  10.  
  11. On Oldsmobile vehicles use J-35731 Fuel Sender Spanner Wrench, or equivalent, to remove the fuel sender assembly retaining cam (lock ring). Then remove the sender assembly and O-ring. Discard the O-ring.
  12.  
  13. On Chevrolet vehicles, remove the fuel sender assembly retaining snapring. Expect the sender to spring-up when the snapring is removed.
  14.  


CAUTION
Do not handle the fuel sender assembly by the fuel pipes. The joints are very fragile. The amount of leverage generated by handling the fuel pipes could damage the joints. This is especially true of some Oldsmobile application which use long fuel pipes which are easily damaged.

  1. Carefully remove the sende