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Home >> Pontiac >> 2004 >> GTO Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls -- 5.7L -- (Introduction) >> Repair Instructions >> Fuel Sender Assembly Replacement >> Removal Procedure
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Removal Procedure

  1. Remove the fuel tank assembly. Refer to Fuel Tank Replacement .
    2. Fig 1: Locating Fuel Tank Pressure Sensor Connector, Fuel Pump Connector & EVAP Vapor Hose Quick-Connector
    GM1372275Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the fuel tank pressure sensor connector (1), the fuel pump connector (2), and the EVAP vapor hose quick connector (3), from the modular fuel pump and sender assembly cover (4).
    3. Fig 2: View Of Modular Fuel Pump & Sender Assembly Ground Terminal
    GM1372276Courtesy of GENERAL MOTORS CORP.
  3. Remove the flanged nut securing the modular fuel pump and sender assembly ground terminal to the fuel tank flange stud, and remove the fuel tank wiring harness.
    4. Fig 3: Removing/Installing Cover Retainer Lock Ring
    GM1372244Courtesy of GENERAL MOTORS CORP.
  4. Using the J 45722  (2) and a half-inch breaker bar (1), remove the cover retainer lock ring (3) by turning in a counter-clockwise direction. See Special Tools and Equipment .
    5. Fig 4: View Of Modular Fuel Pump & Sender Assembly
    GM1372246Courtesy of GENERAL MOTORS CORP.
  5. Partially lift the modular fuel pump and sender assembly away from the fuel tank, taking care not to damage the fuel level sender assembly.
  6. Disconnect the fuel tank EVAP vapor line quick connector from the underside of the modular fuel pump and sender assembly cover.
  7. Insert hand into the fuel tank opening and disconnect the fuel feed line quick connector.
  8. Remove the modular fuel pump and sender assembly.
    9. IMPORTANT:
    • Fuel vapor remains in the tank even when completely empty. Seal the opening in the fuel tank using a suitable plug and place a suitable cover over the plug to prevent any foreign matter from entering
    • Check the underside of the reservoir to ensure that there are 3 rubber isolator feet attached to the bottom. If one or more are missing, retrieve each from within the fuel tank and reinstall
  9. Remove and discard the modular fuel pump and sender assembly to fuel tank seal.
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