Remove the fuel tank cap and properly relieve the fuel system pressure before performing any work on the fuel system or fuel system related components. After the pressure has been released a small amount of fuel may be released when servicing a component. In order to reduce the risk of injury cover the component with a shop towel before disconnection. This will catch any fuel that may leak out. Properly dispose of the shop towel.
Before servicing the vehicle, refer to the Precautions Section.
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.
If working near and/or around the SRS system and components, be sure to properly disable the SRS system. See disarming/arming the SRS system.
Disconnect the negative battery cable.
Properly relieve the fuel system pressure.
Drain the fuel tank to an acceptable level.
Raise and support the vehicle safely.
Remove the fuel tank.
Fig. Fuel tank and related components sedan (1 of 2)-1991-1993
Fig. Fuel tank and related components sedan (2 of 2)-1991-1993
Fig. Fuel tank and related components station wagon (1 of 2)-1991-1993
Fig. Fuel tank and related components station wagon (2 of 2)-1991-1993
Remove the fuel tank sending unit from the fuel tank. Discard the O-ring.
Fig. Fuel level sensing unit and related components sedan-1991-1993
Fig. Fuel level sensing unit and related components station wagon-1991-1993
Fig. Fuel level sensing unit exploded view-1991-1993
Be sure to use new fasteners, as required.
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread sealer are identified. Do not use paints, lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners.
Installation is the reverse of the removal procedure.
Turn the ignition
for 2 seconds,
for 10 seconds, the
and inspect the system for leaks.
Using the GM diagnostic scan tool or aftermarket equivalent reprogram the necessary systems and components. Be sure to follow the scan tool manufacturer-s directions.