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Home >> Saturn >> 2010 >> Sky Base, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 2.4L - Repair Instructions >> Repair Instructions >> Fuel Pump Module Replacement >> Removal Procedure
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Removal Procedure

WARNING: 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.
CAUTION: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
    Fig 1: View Of Fuel Pump Module Unit Access Cover
    GM1594369Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH 48027-100)  or Fuel Pressure Relief (Without CH 48027-100) .
  2. Remove the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement (Convertible) .
  3. Remove the fuel sending unit access cover bolts.
  4. Remove the access cover.
    5. Fig 2: Identifying Fuel Tank Sensors Electrical Connectors
    GM1594359Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the fuel sender electrical connector (3).
  6. Disconnect the fuel pressure sensor electrical connector (5).
    7. Fig 3: Identifying Fuel Tank Pressure Sensor
    GM1594372Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel fill pipe evaporative emission (EVAP) pipe quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the fuel feed pipe quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service .
    9. Fig 4: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    CAUTION: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
    CAUTION: 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.
    NOTE:
    • The fuel sender assembly may spring up from its position.
    • When removing the fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard the fuel sender assembly O-ring and replace it with a new one.
    • Carefully discard the fuel in the reservoir bucket into an approved container.
    NOTE: 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.
  9. 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.
    10. Fig 5: View Of Fuel Sender Assembly
    GM1594373Courtesy of GENERAL MOTORS CORP.
  10. Raise the fuel sender up slightly.
  11. Connect the large EVAP canister quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Remove the fuel sender assembly.
  13. Remove and discard the fuel sender O-ring.
    14. Fig 6: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • 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.
  14. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gauge at 7 points.
  15. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  16. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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