2004 Pontiac Vibe GTFACTORY OEM SERVICE PROCEDURE

Installation Procedure

NOTE: Always reattach the fuel lines and fuel filter with all original type fasteners and hardware.
Do not repair sections of fuel pipes.
    Fig 1: O-Ring, Hold Down Plate, Fuel Sender Assembly And Bolts
    GM828314Courtesy of GENERAL MOTORS CORP.
  1. Position the new fuel sender assembly O-ring (3) on the fuel sender assembly.
  2. Install the fuel sender assembly (4) into the fuel tank.
  3. Install the hold down plate (2) for the fuel sender assembly.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Secure the hold down plate for the fuel sender assembly with the 8 bolts (1).

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

    5. Fig 2: Fuel Tank Vapor Line, Fuel Supply Line, Retaining Clip
    GM828313Courtesy of GENERAL MOTORS CORP.
  5. Install the fuel tank vapor line (2) to the fuel sender fitting.
  6. Install the fuel pipe (3) to the fuel sender fitting.
  7. Secure the fuel pipe (3) with the retaining clip (1).
    8. Fig 3: Connecting/Disconnecting Fuel Sender And FTP Sensor Electrical Connectors
    GM828297Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel sender electrical connector (1) to the fuel sender assembly.
  9. Connect the FTP sensor electrical connector (2) to the fuel sender assembly.
  10. Connect the negative battery cable.
  11. Pressurize the fuel system and check for leaks.
  12. Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
  13. Install the access panel to the rear seat floor.
  14. Relocate the carpet under the seat and the left sill plate area.
  15. Install the sill plate to the left side door opening.
  16. Install the rear seat bottom cushion.
  17. Secure the seat cushion with the two fasteners. Refer to Seat Cushion Replacement - Rear in Seats.
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.