GM 25894461
Fuel Tank

The first step to replace the primary fuel tank module requires removing the fuel tank which exposes the primary fuel tank module. The quick connect fitting of the fuel feed hose should be disconnected from the module before extracting the fuel feed hose from its retainer to set it aside. Remove the interlock before disconnecting the electrical connector from the module followed by wire harness removal from the retainer and placement aside. Lower the lock ring of the fuel tank module using the J 45722 and a long breaker-bar by turning it counterclockwise to free the ring followed by removing the cam lock ring. You can get to the fuel transfer hose quick connect fitting by taking out part of the primary fuel tank module. Take out the primary fuel tank module from the fuel tank and dispose of the fuel tank module seal. Check the lock ring for damage because it must be replaced if the warping measures more than 0.41 mm (0.016 in). To install the fuel tank module seal effectively you should grasp the transfer hose within the tank before partially installing the primary module. The module requires connection to the fuel transfer hose quick connect fitting by pressing it downward until an alignment with the encapsulated ring occurs before verifying proper lock ring orientation. A technician must employ the J 45722 and a long breaker-bar to install the lock ring through clockwise rotation until full insertion. Safely connect the electrical connector to the module then install the wire harness to its retainer next to connecting the fuel feed hose quick connect fitting to the module followed by reinstalling the fuel feed hose to the retainer for completing the fuel tank installation.

Remove the secondary fuel tank module and its seal, ensuring not to reuse the seal.

Access the fuel transfer hose quick connect fitting and disconnect it.

Inspect the lock ring for damage; if it is warped beyond 0.41 mm (0.016 in), replace it.

Using the Fuel Tank Sender Wrench (J 45747), rotate the cam lock ring clockwise until fully seated, avoiding contact with the fuel pipes.

Access the fuel transfer hose quick connect fitting and disconnect it, then fully remove the module from the fuel tank and discard the fuel tank module seal.