Removal Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

Fig 1: Fuel Feed Line

Courtesy of GENERAL MOTORS CORP.

Remove the secondary fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement - Secondary .
Disconnect the fuel feed line quick connect fitting (1) from the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .
Open the retaining clip (3) on the fuel tank and remove the fuel feed line (2).

Fig 2: Vapor Line Quick Connect Fittings

Courtesy of GENERAL MOTORS CORP.

Disconnect the engine wiring harness electrical connectors (2) from the fuel tank fuel pump primary module and the fuel tank pressure sensor.
Disconnect the vapor line quick connect fittings (1) from the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .

Fig 3: Identifying Special Tools - J 45722

Courtesy of GENERAL MOTORS CORP.

Install the J 45722 (1) to the fuel tank fuel pump module lock ring. See Special Tools .

Fig 4: Identifying Lock Ring

Courtesy of GENERAL MOTORS CORP.

CAUTION: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

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.

Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank fuel pump module lock ring. See Special Tools .

Fig 5: Identifying Special Tools - J 45722

Courtesy of GENERAL MOTORS CORP.

Remove the J 45722 (1). See Special Tools .

Fig 6: Fuel Tank Fuel Pump Module Lock Ring

Courtesy of GENERAL MOTORS CORP.

Remove the fuel tank fuel pump module lock ring (1).

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.

Slowly raise the module (2) until the fuel level sensor float arm is just visible.

NOTE: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
Carefully discard the fuel in the module reservoir bucket into an approved fuel container.

NOTE: DO NOT reuse the old fuel tank module O-ring seal.

Remove and discard the fuel tank fuel pump module O-ring seal (3).
If replacing the fuel tank fuel pump module, remove the fuel level sensor, if required. Refer to Fuel Level Sensor Replacement .

Fig 7: Checking Lock Ring For Flatness

Courtesy of GENERAL MOTORS CORP.

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 lock ring.
Check the lock ring for flatness.

Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.