Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

Remove the fuel tank. Refer to Fuel Tank Replacement (Prior to VIN 4S558922 (100mm Sender)) Fuel Tank Replacement (VIN 4S558922 and Later (130mm Sender)) .

Fig 1: View Of Fuel Sender Module Electrical Connectors

Courtesy of GENERAL MOTORS CORP.

Disconnect the fuel sender module electrical connectors.

Fig 2: Identifying Fuel Pipes At Fuel Sender

Courtesy of GENERAL MOTORS CORP.

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.

Disconnect the fuel pipes from the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

Fig 3: View Of J 45722

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. Secure the fuel tank in order to prevent fuel tank rotation.

Use the J 45722 (1) and a long breaker-bar in order to unlock the fuel sender lock ring.

Fig 4: Identifying Fuel Sender Lock Ring

Courtesy of GENERAL MOTORS CORP.

Remove the fuel sender lock ring (1) and the fuel sender (2) from the fuel tank.
Remove and discard the fuel sender seal (3).
Remove the fuel level sensor from the fuel sender module. Refer to Fuel Level Sensor Replacement (Prior to VIN 4S558922 (100mm Sender)) Fuel Level Sensor Replacement (VIN 4S558922 and Later (130mm Sender)) .