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Home >> Saturn >> 2009 >> Aura Green Line >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 2.4L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Assembly Procedure

Assembly 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.
NOTE:
  • 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.
  • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW fuel pump module.
  • Inspect the lock ring for flatness as best as possible. If the lock ring is warped, replace the fuel pump module.
    Fig 1: View Of Fuel Tank Shield & Retainers
    GM1796296Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank shield and retainers.
    2. Fig 2: View Of Fuel Pump Module
    GM1796302Courtesy of GENERAL MOTORS CORP.
  2. Clean any contamination from the male pipe ends of the fuel pump module.
  3. Place a NEW fuel tank module seal onto the fuel tank.
  4. Insert the fuel pump module into the fuel tank allowing the sensor arm and float to clear the module opening.
  5. Lower the module down into the fuel tank until the fuel tank vent pipe quick connect fitting can be connected.
    6. Fig 3: Identifying Fuel Tank Vent Pipe Quick Connect Fitting
    GM1796294Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel tank vent pipe quick connect fitting (1) at the module cover. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Press the fuel tank module downward.
    8. Fig 4: View Of Special Tool On Fuel Pump Module Lock Ring
    GM1796288Courtesy of GENERAL MOTORS CORP.
  8. Install the J 45722  to the fuel pump module lock ring. See Special Tools .
    9. Fig 5: View Of Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  9. Using the J 45722  and a long breaker-bar, rotate the lock ring in a clockwise direction in order the lock the lock ring. See Special Tools .
  10. Remove the J 45722  from the fuel pump module lock ring. See Special Tools .
    11. Fig 6: View Of EVAP Canister
    GM1790139Courtesy of GENERAL MOTORS CORP.
  11. Install the EVAP canister and the EVAP canister vent solenoid as an assembly. Slide the EVAP canister vent solenoid onto the fuel tank bracket until the retaining tab is engaged.
    12. CAUTION: Refer to Fastener Caution .
  12. Install the EVAP canister bolt and tighten to 3.5 N.m (31 lb in).
    13. Fig 7: View Of Fuel Tank Fuel Pump Module Wiring Harness
    GM1796230Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel tank fuel pump module wiring harness.
    14. Fig 8: Identifying Fuel Pump Wiring Harness Connector
    GM1796263Courtesy of GENERAL MOTORS CORP.
  14. Connect the fuel tank fuel pump module wiring harness electrical connector (1) to the EVAP canister vent solenoid.
    15. Fig 9: Identifying Fuel Pump Module Wiring Harness Connectors
    GM1796271Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) to the fuel pressure sensor, if equipped and the module.
    16. Fig 10: View Of Fuel Tank Vent Pipe
    GM1796282Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel tank vent pipe to the fuel tank.
    17. Fig 11: Identifying Fuel Tank Vent Pipe Quick Connect Fittings
    GM1795288Courtesy of GENERAL MOTORS CORP.
  17. Connect the fuel tank vent pipe quick connect fitting (1) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  18. Connect the fuel tank vent pipe quick connect fittings (3, 4) to the module. Refer to Plastic Collar Quick Connect Fitting Service .
    19. Fig 12: Identifying Fuel Tank Attachments
    GM1795283Courtesy of GENERAL MOTORS CORP.
  19. Install the fuel feed pipe to the retaining features (2, 4) built into the fuel tank.
  20. Install the fuel tank vent pipe to the retaining features (1) built into the fuel tank.
  21. Install the fuel tank fuel pump module wiring harness to the retaining features (5) built into the fuel tank.
  22. Install the EVAP emission canister purge pipe to the retaining features (3) built into the fuel tank.
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