2004 Pontiac GTO StandardFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    IMPORTANT: Upon installation of the modular fuel pump and sender assembly, only use the custom sized O-rings as supplied with modular fuel pump and sender assembly replacement parts kit. Do not use off-the-shelf O-rings.
  1. Before installation into the fuel tank, check the fuel sender float position.
    • Stand the assembly upright on a flat surface
    • Measure the distance between the middle of the fuel sender float and the flat surface
    • If required, the float position should be corrected, through careful adjustment of the float arm.
    • Float Position:  7 mm to 14 mm.
  2. Clean any dirt and foreign materials from the fuel tank seal recess and position a new seal in the recess.
  3. Install the modular fuel pump and sender assembly into the fuel tank, taking care not to damage the fuel level sender float and arm in the process.
  4. Insert hand into the fuel tank opening and connect the fuel feed line quick connector.
  5. Connect the fuel tank EVAP vapor line quick connector from the underside of the modular fuel pump and sender assembly cover.
    6. Fig 1: Engaging Cover Locator In Tank Opening Slot
    GM1372245Courtesy of GENERAL MOTORS CORP.
  6. Ensure the locator in the cover engages in the slot in the tank opening.
    7. Fig 2: Removing/Installing Cover Retainer Lock Ring
    GM1372244Courtesy of GENERAL MOTORS CORP.
  7. Install the cover retainer lock ring. Use the half-inch breaker bar with J 45722  and rotate the retainer in a clockwise direction until the tangs are engaged. See Special Tools and Equipment .
    8. Fig 3: View Of Modular Fuel Pump & Sender Assembly Ground Terminal
    GM1372276Courtesy of GENERAL MOTORS CORP.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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