2005 Pontiac Aztek Base, FWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Clean the fuel sender sealing flange.
    2. IMPORTANT: Always replace the fuel sender seal when installing the fuel sender assembly.
  2. Install the NEW fuel sender seal to the fuel tank.
    3. IMPORTANT: Do not fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.
  3. Install the fuel sender and the fuel sender lock ring.
    4. Fig 1: View Of J39765-A
    GM888802Courtesy of GENERAL MOTORS CORP.
  4. Use the J39765-A  (1) in order to install the fuel sender lock ring. See Special Tools .
    5. Fig 2: Illustrating Proper Handling Of Fuel Pipes
    GM888805Courtesy of GENERAL MOTORS CORP.
  5. Install the fuel pipes to the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    6. Fig 3: View Of Fuel Sender Electrical Connectors
    GM888799Courtesy of GENERAL MOTORS CORP.
  6. Install the fuel sender sensor electrical connectors.
    7. Fig 4: Identifying Fuel Sender Shield
    GM888801Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel sender shield.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the fuel sender shield nuts.

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

  9. Install the fuel tank. Refer to Fuel Tank Replacement .
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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