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Home >> Pontiac >> 2007 >> Vibe Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System & Fuel System - Introduction (2 Of 2) >> Repair Instructions >> Fuel Sender Assembly Replacement >> 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 .
    2. Fig 1: View Of Seat Bottom Cushion
    GM1464194Courtesy of GENERAL MOTORS CORP.
  2. Remove the 2 fasteners (2) of the right side cushion (1) and swing the rear seat bottom cushion (1) up and out of the way.
  3. Remove the sill plate from the right side door opening.
  4. Fold back the carpet in order to maintain metal-to-metal contact while servicing the fuel sender assembly.
    5. Fig 2: View Of Fuel Sender Electrical Connector
    GM1460703Courtesy of GENERAL MOTORS CORP.
  5. Remove the 4 fasteners of the access panel (1) for the fuel sender assembly from the rear seat floor (3).
  6. Lift the access panel (1) and disconnect the fuel sender electrical connector (2) from the fuel sender assembly.
    7. Fig 3: View Of Fuel Line Fitting And Retaining Clip
    GM1460704Courtesy of GENERAL MOTORS CORP.
  7. Remove the retaining clip (1) from the fuel line fitting (2).
    8. Fig 4: View Of Fuel Sender Assembly And Fuel Line
    GM1460705Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the fuel line (1) from the fuel sender assembly.
    9. Fig 5: View Of ORVR Vent Line And Lock Clasp
    GM1460718Courtesy of GENERAL MOTORS CORP.
  9. Unlock the quick connect fitting on-board refueling vapor recovery (ORVR) vent line (1). Refer to Plastic Collar Quick Connect Fitting Service .
    10. Fig 6: View Of ORVR Vent Line And Fuel Sender Assembly
    GM1460719Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the ORVR vent line (2) from the fuel sender assembly (1).
    11. Fig 7: Loosening/Tightening Fuel Sender Assembly Lock Ring
    GM1460720Courtesy of GENERAL MOTORS CORP.
  11. Use the CH-47717  fuel lock ring remover tool (1) in order to loosen the fuel sender assembly lock ring. See Special Tools .
  12. Clean the area around the fuel and vent lines and the fuel sender assembly in order to prevent possible fuel contamination during removal.
    13. Fig 8: View Of Fuel Sender, Lock Ring & Floor Panel Opening
    GM1465529Courtesy of GENERAL MOTORS CORP.
  13. Remove the lock ring (1).
    14. IMPORTANT: Do not spill residual fuel or damage the fuel level sensor float while rotating and tilting the sender assembly during removal.
  14. Remove the fuel sender assembly (2) from the fuel tank.
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