LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Saturn >> 2007 >> Relay 3.9 1 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Module Replacement (Short Wheel Base) >> Removal Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removal Procedure

    Fig 1: Identifying Fuel Sender Assembly (Short Wheel Base)
    GM1544792Courtesy of GENERAL MOTORS CORP.
    NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement (Long Wheel Base)  or Fuel Tank Replacement (Short Wheel Base) .
  2. Disconnect the fuel tank harness electrical connectors (4) from the module.
  3. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
  4. Disconnect the fuel feed pipe quick connect fitting (3) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Disconnect the evaporative emission (EVAP) pipe quick connect fittings (5, 6) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
    6. Fig 2: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    NOTE: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
    NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
    IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
  6. Use the J 45722  and a long breaker-bar in order to unlock the fuel sender lock ring. See Special Tools . Turn the fuel sender lock ring in a counterclockwise direction.
    7. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
  7. Remove the fuel tank module and seal from the fuel tank.
  8. Discard the fuel tank module seal.
  9. Clean the fuel tank module sealing surfaces.
    10. Fig 3: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.
    • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
    • Check the lock ring for flatness.
  10. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
  11. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  12. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
scientia non olet · About LEMON Manuals