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Home >> Saturn >> 2004 >> Ion Red Line >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls (Introduction) >> Repair Instructions >> Fuel Pump Module Replacement >> Removal Procedure
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Removal Procedure

CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.
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.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
    2. IMPORTANT: Take note of the positioning of the fuel tank rear shield prior to releasing the pump module pipe retainer.
  2. Release the retaining tab on the fuel tank retainer used to secure the fuel pump module pipes in position on the tank.
  3. Release the fuel pump module electrical harness from the retaining slot on the tank.
  4. Disconnect the fuel pump module harness electrical connector from the fuel tank pressure sensor.
    5. Fig 1: View Of Fuel Pump Module And Fuel Tank Pressure Sensor Electrical Connectors
    GM889969Courtesy of GENERAL MOTORS CORP.
  5. Using the SA9156E  , or J 39765  (1), carefully rotate to release the fuel pump module retaining lock ring. See Special Tools and Equipment .
    6. Fig 2: Using SA9156E Or J 39765 To Lock/Unlock Fuel Pump Module Retaining Ring
    GM889980Courtesy of GENERAL MOTORS CORP.
  6. Remove the fuel pump module retaining lock ring, by sliding the ring over the module pipes and electrical harness.
    7. Fig 3: View Of Fuel Pump Module Retaining Lock Ring
    GM889983Courtesy of GENERAL MOTORS CORP.
  7. Slowly raise the fuel pump module assembly until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening.
    IMPORTANT: When removing the fuel pump module assembly from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm.
  8. Tilt the pump module toward the rear of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module from the tank.
  9. Carefully discard the fuel in the pump module reservoir bowl into an approved fuel container.
    10. IMPORTANT: Do NOT reuse the old fuel pump module-to-fuel tank seal.
  10. Remove and discard the fuel pump module-to-fuel tank seal (1).
    11. Fig 4: Identifying Fuel Pump Module-To-Fuel Tank Seal
    GM889986Courtesy of GENERAL MOTORS CORP.
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