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Home >> Pontiac >> 2006 >> GTO Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 6.0L - Introduction (2 Of 2) >> 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.
    NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
    NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
    IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
  4. Using the J 45722  (2) and a half-inch breaker bar (1), remove the cover retainer lock ring (3) by turning in a counterclockwise direction. See Special Tools .
    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 evaporative emission (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.
    10. Fig 5: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.
    • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
    • Check the lock ring for flatness.
  10. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
  11. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  12. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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