Solstice 2006-2008, Sky 2007-2008

Fuel Pump

Print

Removal & Installation




CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


CAUTION
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    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.


    WARNING
    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.

  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the rear compartment trim panel.
  6.  
  7. Remove the fuel sending unit access cover bolts.
  8.  
  9. Remove the access cover.
  10.  
  11. Disconnect the fuel sender electrical connector.
  12.  
  13. Disconnect the fuel pressure sensor electrical connector.
  14.  
  15. Disconnect the fuel fill pipe evaporative emission (EVAP) pipe quick connect fitting.
  16.  
  17. Disconnect the fuel feed pipe quick connect fitting.
    WARNING
    Avoid damaging the lockring. Use only tool J-45722 to prevent damage to the lockring.


    WARNING
    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 lockring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.



    Click image to see an enlarged view

    Fig. Tool J-45722

  18.  
  19. Use tool J 45722 and a long breaker-bar in order to unlock the fuel sender lockring. Turn the fuel sender lockring in a counterclockwise direction.
  20.  
  21. Raise the fuel sender up slightly.
  22.  
  23. Connect the large EVAP canister quick connect fitting.
  24.  
  25. Remove the fuel sender assembly.
  26.  
  27. Remove and discard the fuel sender O-ring.
    NOTE
    Some lockrings were manufactured with DO NOT REUSE stamped into them. These lockrings may be reused if they are not damaged or warped.


    NOTE
    Inspect the lockring for damage due to improper removal or installation procedures. If damage is found, install a NEW lockring.


    NOTE
    Check the lockring for flatness.



    Click image to see an enlarged view

    Fig. Check the lockring for flatness

  28.  
  29. Place the lockring on a flat surface. Measure the clearance between to lockring and the flat surface using a feeler gage at 7 points.
  30.  
  31. If the warpage is less than 0.41 mm (0.016 in.), the lockring does not require replacement.
  32.  
  33. If the warpage is greater than 0.41 mm (0.016 in.), the lockring must be replaced.

    Click image to see an enlarged view

    Fig. Fuel pump module

  34.  

To install:

  1. Install a NEW fuel sender O-ring.
  2.  
  3. Install the fuel sender assembly.
    NOTE
    Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lockring if necessary. Do not apply any type of lubrication in the seal groove. Ensure the lockring is installed with the correct side facing upward. A correctly installed lockring will only turn in a clockwise direction.

  4.  
  5. Using the tool, rotate the fuel sender assembly lockring clockwise until the ring is locked into place on the fuel tank.
  6.  
  7. Connect the large EVAP canister quick connect fitting.
  8.  
  9. Connect the fuel feed pipe quick connect fitting.
  10.  
  11. Connect the fuel fill pipe EVAP pipe quick connect fitting.
  12.  
  13. Connect the fuel pressure sensor electrical connector.
  14.  
  15. Connect the fuel sender electrical connector.
  16.  
  17. Install the access cover.
  18.  
  19. Install the fuel sending unit access cover bolts.
  20.  
  21. Install the rear compartment trim panel.
  22.  
  23. Refill the tank.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Inspect for fuel leaks through the following steps:

    Turn the ignition to the ON position for 2 seconds.
     
    Turn the ignition to the OFF position for 10 seconds.
     
    Turn the ignition to the ON position
     
    Check for fuel leaks.
     

  28.  

 
label.common.footer.alt.autozoneLogo