Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Pontiac Sunfire AutomaticFACTORY OEM SERVICE PROCEDURE
Removal Procedure
CAUTION:
In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.
- Remove the fuel tank (4). Refer to Fuel Tank Replacement .
- Disconnect the wiring harness from the fuel pump module and the fuel tank pressure (FTP) sensor.IMPORTANT:
- The modular fuel sender assembly may spring up.
- When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float.
- Carefully discard the reservoir fuel into an approved container.
- Use the J 39765 in order to press down and rotate the retaining ring (1).
- Remove the fuel pump module assembly.
- Remove the fuel level sensor from the fuel pump module assembly. Refer to Fuel Level Sensor Replacement.
Factory Service Tools
Use the Manual With the Right Hardware
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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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