ASI Resolution - Rumble, Popping Noise From Rear of Vehicle with Low Fuel Levels (Replace Fuel Pump)

This bulletin is being revised to provide the correction information for Advanced Service Information Bulletin 05-06-04-001. Please discard Corporate Bulletin Number 05-06-04-001 (Section 06 -- Engine/Propulsion System).

Some customers may comment on an intermittent rumble and or popping noise from the rear of the vehicle. This condition will occur when the fuel level is at approximately 7.5-17L (2-4.5 Gallons) and vehicle is idling. Filling the fuel tank will temporarily eliminate this noise condition until the fuel reaches the suspect level again.

Air is being ingested into the fuel pump during low fuel conditions causing cavitation of the fuel pump.

Replace the fuel pump without fuel level sender using the procedure below.

1. Remove the fuel tank. Refer to the Fuel Tank Replacement procedure in the Engine Controls sub-section of the service manual (SI Document ID # 1381516 (LaCrosse, Allure) or # 1554451 (Grand Prix)).

Notice: Avoid damaging the lock ring. Use only the J 45722 to prevent damage to the lock ring.

2. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counterclockwise direction.
3. Remove the fuel sender assembly from the fuel tank.
4. Clean the fuel sender assembly O-ring sealing surface on the tank.

Important: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.

Important: Inspect the lock ring for damage due to improper removal or installation. If damage is found, install a new lock ring.

5. Disconnect the fuel level sensor electrical connector.
6. Remove the fuel level sensor from the fuel sender (pump) assembly.
7. Install the original fuel level sensor to the new fuel sender (pump) assembly
8. Connect the fuel level sensor electrical connector.
9. Position the new fuel sender O-ring seal onto the fuel tank.
10. Install the fuel sender into the fuel tank. Ensure that the align tab is in the proper location.
11. Push down the fuel sender and position the lock ring onto the fuel tank.

Important: Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

12. Use the J 45722 in order to install the fuel sender lock ring. Turn the lock ring in a clockwise direction.
13. Install the fuel sender assembly to the fuel tank.
14. Install the fuel tank. Refer to the Fuel Tank Replacement procedure in the Engine Controls sub-section of the service manual (SI Document ID # 1381516 (LaCrosse, Allure) or # 1554451 (Grand Prix)).

For vehicles repaired under warranty, use: