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Home >> Pontiac >> 2004 >> Vibe Base, AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System (Introduction) - 1.8L (LV6) >> Repair Instructions >> Fuel Sender Assembly Replacement (AWD) >> Removal Procedure

Removal Procedure

CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
CAUTION: Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.
CAUTION: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.
CAUTION: Remove the rear compartment floor trim to provide technician contact with the vehicle's metal surfaces. Failure to remove the rear compartment floor trim may cause a static electricity discharge to ignite any fuel vapor resulting in personal injury and vehicle damage.
CAUTION: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:
  • Use forced air ventilation such as a fan set outside of the trunk.
  • Plug or cap any fuel system openings in order to reduce fuel vapor formation.
  • Clean up any spilled fuel immediately.
  • Avoid sparks and any source of ignition.
  • Use signs to alert others in the work area that fuel system work is in process.
NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
  • The fuel pipe connections
  • The hose connections
  • The areas surrounding the connections
IMPORTANT:
  • Always replace the fuel sender assembly O-rings when reinstalling the fuel sender assembly.
  • Always maintain cleanliness when servicing fuel system components.
  • Do not bend the arm of the fuel gage float while removing the fuel sender assembly.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure (FWD)  or Fuel Pressure Relief Procedure (AWD) .
    2. Fig 1: (FTP) Sensor And Fuel Sender Electrical Connector (AWD)
    GM828353Courtesy of GENERAL MOTORS CORP.
  2. Remove the two fasteners and swing the rear seat bottom cushion up and out of the way. Refer to Seat Cushion Replacement - Rear in Seats.
  3. Remove the sill plate from the left side door opening.
  4. Fold back the carpet in order to maintain metal-to-metal contact while servicing the fuel sender assembly.
  5. Remove the access panel for the fuel sender assembly from the rear seat floor. The panel is held in place by a butyl caulk seal.
  6. Disconnect the fuel sender electrical connector (2) from the fuel sender assembly.
  7. Disconnect the FTP sensor electrical connector (1) from the fuel sender assembly.
    8. Fig 2: Fuel Supply Line And Retaining Clip (AWD)
    GM828355Courtesy of GENERAL MOTORS CORP.
  8. Remove the retaining clip (2) from the fuel line fitting.
  9. Remove the fuel line (1) from the fuel sender assembly.
    10. Fig 3: Hold Down Plate, O-Ring Sealing Surfaces, Fuel Sender Assembly And Bolts (AWD)
    GM828357Courtesy of GENERAL MOTORS CORP.
  10. Remove the 8 bolts (1) retaining the hold down plate (2) for the fuel sender assembly.
  11. Remove the hold down plate (2).
  12. Clean the fuel pipe and the fuel sender assembly to prevent possible fuel contamination during removal.
  13. Remove the fuel sender assembly (3) from the fuel tank.
  14. Inspect and clean O-ring sealing surfaces on the fuel sender assembly.
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