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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 >> Disassembly Procedure

Disassembly Procedure

    Fig 1: Identifying Fuel Pump Module Wiring Harness Connectors
    GM1796271Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) from the fuel pressure sensor, if equipped and the module.
    2. Fig 2: Identifying Fuel Pump Wiring Harness Connector
    GM1796263Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the fuel tank fuel pump module wiring harness electrical connector (1) from the EVAP canister vent solenoid.
    3. Fig 3: Identifying Fuel Tank Vent Pipe Quick Connect Fittings
    GM1795288Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the fuel tank vent pipe quick connect fitting (1) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Disconnect the fuel tank vent pipe quick connect fittings (3, 4) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
    5. Fig 4: Identifying Fuel Tank Attachments
    GM1795283Courtesy of GENERAL MOTORS CORP.
  5. Remove the EVAP emission canister purge pipe from the retaining features (3) built into the fuel tank.
  6. Remove the fuel tank fuel pump module wiring harness from the retaining features (5) built into the fuel tank.
  7. Remove the fuel tank vent pipe from the retaining features (1) built into the fuel tank.
  8. Remove the fuel feed pipe from the retaining features (2, 4) built into the fuel tank.
    9. Fig 5: Identifying EVAP Canister Vent Solenoid & Retaining Bracket
    GM1796275Courtesy of GENERAL MOTORS CORP.
  9. Insert and gently push a small flat-bladed tool between the EVAP canister vent solenoid and the retaining bracket, disengaging the retaining tab (1).
    10. Fig 6: View Of EVAP Canister
    GM1796277Courtesy of GENERAL MOTORS CORP.
  10. Remove the EVAP canister bolt.
  11. Remove the fuel tank fuel pump module wiring harness from around the EVAP canister.
  12. Remove the EVAP canister and EVAP canister vent solenoid as an assembly.
    13. Fig 7: View Of Fuel Tank Fuel Pump Module Wiring Harness
    GM1796230Courtesy of GENERAL MOTORS CORP.
  13. Remove the fuel tank fuel pump module wiring harness.
    14. Fig 8: View Of Fuel Tank Vent Pipe
    GM1796282Courtesy of GENERAL MOTORS CORP.
  14. Remove the fuel tank vent pipe from the fuel tank.
    15. Fig 9: View Of Special Tool On Fuel Pump Module Lock Ring
    GM1796288Courtesy of GENERAL MOTORS CORP.
  15. Install the J 45722  to the fuel pump module lock ring. See Special Tools .
    16. Fig 10: View Of 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: 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.
  16. Using the J 45722  and a long breaker-bar, rotate the lock ring in a counterclockwise direction in order to unlock the lock ring. See Special Tools .
    17. Fig 11: Identifying Fuel Tank Vent Pipe Quick Connect Fitting
    GM1796294Courtesy of GENERAL MOTORS CORP.
  17. Remove the J 45722  from the fuel pump module lock ring. See Special Tools .
  18. Lift the fuel pump module up slightly in order to disconnect the fuel tank vent pipe quick connect fitting (1) from the module cover. Refer to Plastic Collar Quick Connect Fitting Service .
    19. Fig 12: View Of Fuel Pump Module
    GM1796302Courtesy of GENERAL MOTORS CORP.
  19. Raise the fuel pump module up from the fuel tank. Tilt the module in order to allow the fuel level sensor arm and float to clear the module opening.
  20. Remove the fuel pump module.
    21. WARNING: 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
  21. Remove and discard the fuel pump module seal.
    22. Fig 13: View Of Fuel Tank Shield & Retainers
    GM1796296Courtesy of GENERAL MOTORS CORP.
  22. Remove the fuel tank shield retainers and shield.
  23. Clean the fuel pump module sealing surfaces.
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