ION, L-Series, S-Series 1999-2005

Fuel Pump

Print

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel tank
     
    Fuel lines from the fuel pump module cover
     
    Fuel pump module retaining ring with a Sending Unit Wrench, J43827
     
    Pull the retaining clip toward the float arm and lift up
     
    Fuel pump straight up from the fuel tank
     
    Fuel pump tank seal and discard the seal
     
    Fuel feed line from the bottom of the fuel pump cover with Clamp Pliers J43914
     
    Fuel pump electrical connector

    Click image to see an enlarged view

    Fig. Remove the fuel pump cover lockring-2.0L, 2.2L and 3.0L engines

     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump feed line to the cover
     
    Fuel pump electrical connector
     
    Fuel pump to the new seal
     
    Fuel pump cover lockring with Tool J-43827
     
    Fuel lines and wiring harness
     
    Fuel tank. Tighten the strap bolts to 18 ft. lbs. (25 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel tank
     
    Fuel lines from the fuel pump module cover
     
    Fuel pump module retaining ring with a Sending Unit Wrench, J43827
     
    Pull the retaining clip toward the float arm and lift up
     
    Fuel pump straight up from the fuel tank
     
    Fuel pump tank seal and discard the seal
     
    Fuel feed line from the bottom of the fuel pump cover with Clamp Pliers J43914
     
    Fuel pump electrical connector

    Click image to see an enlarged view

    Fig. Remove the fuel pump cover lockring

     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump feed line to the cover
     
    Fuel pump electrical connector
     
    Fuel pump to the new seal
     
    Fuel pump cover lockring with Tool J-43827
     
    Fuel lines and wiring harness
     
    Fuel tank. Tighten the strap bolts to 18 ft. lbs. (25 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.
  4.  

Testing



Electrical Test
  1. On the Instrument Panel Junction Block (IPJB), located inside the vehicle beneath the center of the instrument panel, check the condition of fuse No. 12, the 10 amp fuel pump fuse.
  2.  
  3. Locate and remove the fuel pump relay located to the top left of relays in the IPJB. To test the relay, another relay from the same block may be substituted, as they are identical. Using a voltmeter or test light, check for power to the fuel pump relay. With the ignition switch ON or OFF , there should be 12 volts between terminal 30 and ground.
  4.  
  5. Connect a voltmeter or test light to terminal 85 and a suitable ground. When the ignition switch is first turned ON , there will be voltage for about 2 seconds. This is power for the relay coil from the PCM. If there is no voltage, the PCM may be faulty.
  6.  
  7. Locate the fuel pump wiring harness connector in the trunk. When terminals 87 and 30 are jumpered together in the relay socket, there should be 12 volts at terminal A on the connector. The other terminals are for the fuel gauge. The pump ground wire connects directly from the pump to chassis ground.

    Click image to see an enlarged view

    Fig. Remove the access panel from the base of the dashboard center console in order to examine the fuel pump fuse and relay



    Click image to see an enlarged view

    Fig. The fuel pump relay is located in the Instrument Panel Junction Block (IPJB)



    Click image to see an enlarged view

    Fig. Schematic of the fuel pump power supply-all Saturn vehicles

  8.  

Pressure Testing

CAUTION
The following procedure will produce a small fuel spill and fumes. Make sure there is proper ventilation and be sure to take the appropriate fire safety precautions.

  1. Remove the air cleaner or air intake tube assembly for access, then connect fuel pressure gauge SA9127E or an equivalent gauge capable of 0-100 psi (0-690 kPa) to the fuel system test port.
  2.  
  3. Close the fuel gauge shut-off valve. Turn the ignition switch ON to run the fuel pump and build pressure in the system, then turn the ignition OFF again. The pump will only run for about 2 seconds without the engine running. Bleed the air out of the gauge line and cycle the fuel pump again as required to fully bleed the gauge.
  4.  
  5. Start and run the engine to normal operating temperature, then check the gauge for proper operating pressure. At both idle and 3000 rpm, system pressure should be 26-31 psi (179-214 kPa) for the throttle body injection system.
  6.  
  7. Shut the ignition OFF and allow the system to leak down. After about 5 minutes with the pump not running, pressure should leak down no more than 6-8 psi (41-55 kPa).
  8.  
  9. If pressure readings are low, do the following:
    1. Check for bent or pinched lines.
    2.  
    3. Replace the fuel filter.
    4.  
    5. Check for proper fuel pump pressure.
    6.  
    7. Check the fuel pump for flow.
    8.  
    9. Substitute a known good fuel pressure regulator.
    10.  

  10.  
  11. If pressure readings are high, do the following:
    1. Inspect for a restricted fuel return line.
    2.  
    3. Substitute a known good fuel pressure regulator.
    4.  

  12.  

 
label.common.footer.alt.autozoneLogo