GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Aveo 🢒 Body 🢒 Instrument Panel, Gages, and Console 🢒 Fuel Sender Assembly Replacement

Removal Procedure

    Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.


    Object Number: 1376161 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1376163 Size: SH
  2. Disconnect the negative battery cable.
  3. Remove the rear seat. Refer to Rear Seat Cushion Replacement .
  4. Remove the fuel pump access cover.

    5. Object Number: 1376164 Size: SH
  5. Disconnect the electrical connector at the fuel pump assembly.
  6. Disconnect the fuel line.
  7. Remove the fuel pump assembly clip.
  8. Remove the fuel pump assembly from the tank.
  9. Remove and discard the gasket.

Installation Procedure

    Object Number: 1376165 Size: SH
  1. Clean the gasket mating surface on the fuel tank.
  2. Position the new gasket in place.
  3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and connector installation.
  4. Install the fuel pump assembly clip.
  5. Connect the fuel pump assembly connector.
  6. Install the fuel pump line.
  7. Install the fuel pump access cover.
  8. Install the EF10 fuse.
  9. Connect the negative battery cable.
  10. Perform an operational check of the fuel pump.
  11. Install the rear seat. Refer to Rear Seat Cushion Replacement .