GM 25899601
Fuel Tank, Driver Side

The process of Fuel Tank module replacement on the left side begins by disconnecting the negative Battery Cable followed by removing the left Fuel Tank and placing it on a suitable work surface. Separate the Fuel Pump jumper harness from the module and disconnect both the jet line insert from the crossover tube at the Fuel Tank and remove the fuel feed line from its welded clip position. Pay attention since the Fuel Pump module possesses spring action which causes it to rise after the removal of the locking ring. The procedure requires removal of the locking ring from the Fuel Pump module with the fuel sender lock ring tool (J39765-A) so the technician can extract the fuel module while retaining both jet lines without harming the fuel sender float arm. Remove the jet lines from their quick-connect connectors installed at the Fuel Pump module inner port before extracting both lines from their retaining cup then removing the module o-ring through the Fuel Tank opening. The jet line insert should be removed through the crossover tube which leads to the Fuel Tank opening. To replace the fuel module assembly one should move the fuel level sender card from the old module into the new one. Place the new jet line insert through the crossover tube to the Fuel Tank opening and fasten it with the Fuel Pump module o-ring at the Fuel Tank opening. The jet line connector needs tape application to gain access while the pump module enters the Fuel Tank. Feed the new pump module into the Fuel Tank until it reaches the midpoint while cautioning against float arm damage. Then use the taped jet line to guide its upward movement through the pump module opening. Attach the jet line connectorless component into the module retainer cup while securing it with the module retaining clip. Pull the tape from the jet line by using a connector but observe that all connectors connect properly. You should attach the Fuel Pump module lock ring to the inner module port after connecting jet line quick-connect connectors. The fuel sender lock ring tool (J39765-A) must be used to achieve full ring engagement of the Fuel Pump module lock ring. Following this complete the fuel line connection into the weld clip at the tank's side. Check the resistance values of the Fuel Pump module using a dmm against empty and full Fuel Tank conditions by inverting the Fuel Tank to measure the readings (40 ohms resistance when empty, 250 ohms when full). Reinstall the left Fuel Tank while connecting the jet line insert connector into the crossover tube to the Fuel Tank opening and attaching the Fuel Pump jumper harness to the Fuel Pump module.

Disconnect the negative battery cable and remove the right fuel tank, placing it on a suitable work surface.