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Home >> Pontiac >> 2006 >> Vibe Base, AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 1.8L (LV6) - Introduction (2 Of 2) >> Repair Instructions >> Fuel Sender Assembly Replacement (AWD) >> Installation Procedure

Installation Procedure

NOTE: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.
Do not repair sections of fuel pipes.
    Fig 1: Hold Down Plate, O-Ring Sealing Surfaces, Fuel Sender Assembly And Bolts (AWD)
    GM828357Courtesy of GENERAL MOTORS CORP.
  1. Position the new fuel sender assembly O-ring (4) on the fuel sender assembly.
  2. Install the fuel sender assembly (3) into the fuel tank.
  3. Install the hold down plate (2) for the fuel sender assembly and secure with the 5 fasteners (1).
    4. Fig 2: Fuel Supply Line,Fuel Sender Fitting and Retaining Clip
    GM1660833Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel pipe (1) to the fuel sender fitting.
  5. Secure the fuel pipe (1) with the retaining clip (2).
  6. Install the protective fuel line cover and secure with the 3 fasteners.
    7. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  7. Tighten all 8 fuel sender assembly fasteners (1).

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

    8. Fig 3: Fuel Supply Line,Fuel Sender Fitting and Retaining Clip
    GM1660831Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel sender electrical connector (1) to the fuel sender assembly.
  9. Connect the negative battery cable.
  10. Pressurize the fuel system and check for leaks.
  11. Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
  12. Install the access panel to the rear seat floor.
  13. Relocate the carpet under the seat and the left sill plate area.
  14. Install the sill plate to the left side door opening.
    15. Fig 4: Seat Bottom Cushion with Two Fasteners
    GM1687760Courtesy of GENERAL MOTORS CORP.
  15. Lower the rear seat bottom cushion.
  16. Secure the seat cushion (1) with the two fasteners (2).

    Tighten the 2 seat cushion fasteners (2).

    Tighten:  Tighten the bolts to 41 N.m (30 lb ft).

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