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Engine Controls and Fuel - 2.0l - Repair Instructions Saturn Sky I final

Testing & Diagnostics 2 illustrations ~13199 words

Description

The engine control module (ECM) learns the idle position of the throttle body to ensure the correct idle operation. Anytime the ECM or the throttle body is replaced, the ECM must learn the idle position. The engine idle may be unstable or a DTC may set if the idle position is not learned.

Conditions for Running the Idle Learn Procedure

  1. DTCs P0121, P0122, P0123, P0221, P0222, P0223, P0638, P2100, P2101, P2105, and P2119 are not set.
  2. The engine speed is less than 40 RPM.
  3. The vehicle speed is 0 km/h (0 mph).
  4. The accelerator pedal position is less than 14.9 percent.
  5. The ignition 1 voltage is more than 10 volts.
  6. The engine coolant temperature is between 5-85°C (41-185°F).
  7. The intake air temperature is between 5-60°C (41-140°F).

Idle Learn Procedure

  1. Turn OFF the ignition for 30 seconds.
  2. Turn ON the ignition, with the engine OFF for 60 seconds.
  3. Turn OFF the ignition.
  4. Turn ON the ignition, with the engine OFF.
  5. Clear the DTCs with a scan tool.

Removal Procedure

  1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
  2. Record the preset radio stations.
  3. Turn the ignition OFF.
  4. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
  5. Remove the left front fender. Refer to «Front Fender Replacement»(/saturn/sky/i-final-2010-2010/remont/exterior-body-panels/#bolted-exterior-body-panels-closures) .
  6. Remove the windshield washer solvent container. Refer to «Windshield Washer Solvent Container Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Windshield Washer Solvent Container Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
  7. Release the engine control module (ECM) bracket upper and lower retaining tabs (1, 2) using a small screwdriver or other suitable tool.
  8. Remove the ECM from the bracket by lifting upward after releasing the tabs.
  9. Disconnect the engine wiring harness electrical connectors (1, 3) from the ECM (2).

Installation Procedure

  1. Connect the engine wiring harness electrical connectors (1, 3) to the ECM (2).
  2. Slide the ECM into the bracket.
  3. Push down on the ECM until the upper and lower retaining tabs (1, 2) snaps into place.
  4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
  5. Install the windshield washer solvent container. Refer to «Windshield Washer Solvent Container Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Windshield Washer Solvent Container Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
  6. Install the left front fender. Refer to «Front Fender Replacement»(/saturn/sky/i-final-2010-2010/remont/exterior-body-panels/#bolted-exterior-body-panels-closures) .
  7. Reset the clock and preset radio stations.
  8. If a NEW ECM was installed, the ECM must be programmed. Refer to «Control Module References»(/saturn/sky/i-final-2010-2010/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .
  9. If equipped with a manual transmission, perform the clutch pedal position sensor learn procedure. Refer to «Clutch Pedal Position Sensor Learn»(/saturn/sky/i-final-2010-2010/remont/manual-trans/#manual-transmission-aisin-ar5__clutch-pedal-position-sensor-learn) .
  1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
  2. Remove the heat shield from the around the electrical connector, if necessary.
  3. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.
  4. Remove the ECT.
  1. Install the ECT and tighten to 20 N.m (15 lb ft).
  2. Connect the engine wiring harness electrical connector (3) to the ECT sensor.
  3. Install the heat shield around the electrical connector, if necessary.
  4. Fill the cooling system as needed. Refer to «Cooling System Draining and Filling (GE-47716)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (2.4L LE5)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (Static Fill-LNF)»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
  1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.
  2. Remove the MAF sensor screws.
  3. Remove the MAF sensor.
  1. Install the MAF sensor.
  2. Install the MAF sensor screws and tighten to 0.6 N.m (5 lb in).
  3. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
  1. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor.
  2. Remove the MAP sensor bolts.
  3. Remove the MAP sensor and O-ring seal from the intake manifold.
  1. Lubricate the O-ring seal with clean engine oil.
  2. Install the MAP sensor to the intake manifold.
  3. Install the MAP sensor bolts and tighten to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (2) to the MAP sensor.

Special Tools

J 39194 Oxygen Sensor Wrench

  1. Open the hood.
  2. Remove the connector position assurance (CPA) retainer.
  3. Disconnect the engine wiring harness electrical connector (1) from the HO2S electrical connector (3).
  4. Remove the HO2S electrical connector clip (2) from the camshaft cover.
  5. Using the J 39194 , remove the position 1 HO2S.
  1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953 or equivalent.
  2. Using the J 39194 , install the position 1 HO2S and tighten to 42 N.m (31 lb ft).
  3. Connect the engine wiring harness electrical connector (1) to the HO2S electrical connector (3).
  4. Install the HO2S electrical connector clip (2) to the camshaft cover.
  5. Install the CPA retainer.
  6. Close the hood.

J 39194 Oxygen Sensor Wrench

  1. Open the hood.
  2. Remove the connector position assurance (CPA) retainer.
  3. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (2).
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
  5. Using the J 39194 , remove the position 2 HO2S.
  1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953 or equivalent.
  2. Using the J 39194 , install the position 2 HO2S and tighten to 42 N.m (31 lb ft).
  3. Lower the vehicle.
  4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (2).
  5. Install the CPA retainer.
  6. Close the hood.
  1. Remove the knee bolster. Refer to «Knee Bolster Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#instrument-panel-trim-console-trim) or «Knee Bolster Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#instrument-panel-trim-console-trim) .
  2. Disconnect the accelerator pedal position (APP) sensor electrical connector.
  3. Remove the APP sensor nuts.
  4. Remove the APP sensor from the vehicle.
  1. Install the APP sensor to the vehicle.
  2. Install the APP sensor nuts and tighten to 10 N.m (89 lb in).
  3. Connect the APP sensor electrical connector.
  4. Confirm that the APP sensor connector locking clip is fully secured.
  5. Verify the operation of the accelerator pedal.
  6. Install the knee bolster. Refer to «Knee Bolster Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#instrument-panel-trim-console-trim) or «Knee Bolster Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#instrument-panel-trim-console-trim) .
  1. Remove the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the engine wiring harness electrical connector (1) from the electronic throttle control (ETC).
  3. Disconnect the engine wiring harness electrical connector (1) from the brake booster auxiliary pump.
  4. Remove the brake booster auxiliary pump electrical connector clip from the bracket.
  5. Remove the throttle body bolts.
  6. Remove the throttle body and seal from the intake manifold.
  1. Inspect the throttle body seal, and replace if necessary.
  2. Position the throttle body to the intake manifold.
  3. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (1) to the brake booster auxiliary pump.
  5. Install the brake booster auxiliary pump electrical connector clip to the bracket.
  6. Connect the engine wiring harness electrical connector (1) to the ETC.
  7. Install the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

Throttle Body Cleaning

CAUTIONDo not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate.
CAUTIONDo not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.
  1. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces.
  3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner P/N 1052626 (Canadian P/N 993026) or AC-Delco Carburetor Tune-up Conditioner P/N X66-P, or an equivalent product.
  4. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

Fuel Pressure Relief (Low Pressure without Special Tool)

WARNINGRemove 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. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  2. Remove the engine cover, if required.
  3. Remove the fuel service port cap.
  4. Wrap a shop towel around the fuel service port and using a small flat bladed tool, depress (open) the fuel rail test port valve.
  5. Remove the shop towel from around the fuel service port, and place in an approved gasoline container.
  6. Install the fuel service port cap.
  7. Install the engine cover, if required.
  8. Tighten the fuel fill cap.

CH-48027 Digital Pressure Gauge. See Special Tools .

Fuel Pressure Relief Procedure

  1. Remove the engine cover, if required.
  2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  3. Remove the fuel service port cap.
  4. Wrap a shop towel around the fuel service port.
  5. Connect the CH-48027-3 (4) to the fuel service port.
  6. Connect the CH-48027-2 (2) to the CH-48027-3 (4).
  7. Place the hose on the CH-48027-2 (2) into an approved gasoline container.
  8. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail.
  9. Close the valve on the CH-48027-2 (2).
  10. Remove the hose on the CH-48027-2 (2) from the approved gasoline container.
  11. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
  12. Disconnect the CH-48027-3 (4) from the fuel service port.
  13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  14. Install the fuel service port cap.
  15. Install the engine cover, if required.
  16. Tighten the fuel fill cap.

CH-48027-100 Digital Pressure Gauge

  1. Remove the engine cover, if required.
  2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  3. Remove the fuel rail service port cap.
  4. Wrap a shop towel around the fuel service port.
  5. Connect the CH-48027-3 (3) to the fuel service port.
  6. Connect the CH-48027-2 (2) to the CH-48027-3 (3).
  7. Place the hose on the CH-48027-2 (2) into an approved gasoline container.
  8. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail.
  9. Close the valve on the CH-48027-2 (2).
  10. Remove the hose on the CH-48027-2 (2) from the approved gasoline container.
  11. Disconnect the CH-48027-2 (2) from the CH-48027-3 (3).
  12. Disconnect the CH-48027-3 (3) from the fuel service port.
  13. Remove the shop towel from around the fuel service port, and place in an approved gasoline container.
  14. Install the fuel service port cap.
  15. Install the engine cover, if required.
  16. Tighten the fuel fill cap.

Fuel Pressure Relief (High Pressure Side)

WARNINGFuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure.
  1. Install a scan tool to the vehicle and command the fuel pump relay OFF, allowing the low pressure fuel pump to shut off.
  2. Start the vehicle and allow the engine to idle until the engine stops. The engine will stop in approximately 20-30 seconds.
  3. Turn the ignition OFF.
  4. Using the scan tool, verify that there is little to no fuel pressure, if there still is fuel pressure repeat step 2.
  5. Remove the high pressure fuel line. Refer to «Fuel Feed Intermediate Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

CH-48027-100 Digital Pressure Gauge

  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
  3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027-100 , refer to the manufacture's directions.
  1. Relieve the fuel system pressure, if required. Perform the following steps: WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Wrap a shop towel around the fuel rail service port. Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH-48027-2 (2). Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
  3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (3).
  4. Disconnect the CH-48027-3 (3) from the fuel rail service port.
  5. Install the fuel rail service port cap.
  6. Install the engine cover, if required.
  7. Tighten the fuel fill cap.

CH-48027 Digital Pressure Gauge. See Special Tools .

  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
  3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 , refer to the manufacture's directions. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
  1. Relieve the fuel system pressure, if required. Perform the following steps: WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Wrap a shop towel around the fuel rail service port. Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH-48027-2 (2). Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
  3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
  4. Disconnect the CH-48027-3 (4) from the fuel rail service port.
  5. Install the fuel rail service port cap.
  6. Install the engine cover, if required.
  7. Tighten the fuel fill cap.

Special Tool

J 37088-A Fuel Line Disconnect Tool Set

  1. Relieve the low side fuel system pressure. Refer to the «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Remove the retainer from the quick-connect fitting.
  3. Blow dirt out of the fitting using compressed air.
  4. Choose the correct tool from the J 37088-A for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs.
  5. Pull the connection apart.
  6. Use a clean shop towel in order to wipe off the male pipe end.
  7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
  1. Apply a few drops of clean engine oil to the male pipe end.
  2. Push both sides of the fitting together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
  4. Install the retainer to the quick-connect fitting.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Using compressed air, blow any dirt out of the quick connect fitting.
  3. This step applies to the Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs.
  4. This step applies to Q release style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting.
  5. This step applies the Squeeze to release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting.
  6. This step also, applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by the arrows on both sides of the plastic ring surrounding the quick connect fitting.
  7. This step applies the Sliding retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. The tab will only move in one direction.
  8. This step applies to the Push down TI style connectors ONLY. Release the fitting by pressing on the tab indicated by the arrow.
  9. Pull the connection apart.
  10. Wipe off the male pipe end using a clean shop towel.
  11. Inspect both ends of the fitting for dirt and burrs.
  12. Clean or replace the components as required.
  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
  3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure.
  1. J 36850 Transjel Lubricant. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
  2. J 42960-2 Fuel Flapper Door Holder. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
  3. J 45004 Fuel Tank Drain Hose. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
WARNINGNever drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion.
WARNINGPlace a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.

Draining Procedure

  1. Remove the fuel fill cap.
  2. Install the J 42960-2 into the fuel fill pipe in order to hold the door open. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
  3. Insert the J 45004 into the fuel tank until the hose reaches the bottom of the fuel tank. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
  4. Use a hand or air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.
CAUTIONCap 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.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining (Non E-85)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Remove the rear compartment trim panel. Refer to «Rear Compartment Trim Panel Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#interior-trim-system-paneling) .
  4. Remove the fuel pump module access cover bolts.
  5. Remove the fuel pump module access cover.
  6. Disconnect the fuel sending unit electrical connector (3).
  7. Disconnect the fuel tank pressure sensor electrical connector (5).
  8. Disconnect the evaporative emission (EVAP) canister vent solenoid electrical connector (2).
  9. Disconnect the fuel pump fuel feed line quick connect fitting (1) from the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  10. Disconnect the EVAP canister purge line quick connect fitting (2) from the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  11. Secure the fuel feed and EVAP purge lines up out of the way.
  12. Remove the fuel fill pipe. Refer to «Fuel Tank Filler Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  13. Disconnect the fuel tank fill pipe EVAP line quick connect fitting (1) from the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  14. Remove the fuel tank fill EVAP line out through the access hole in order to prevent damage to the pipe when removing the tank.
  15. Remove the rear suspension crossmember. Refer to «Rear Suspension Support Crossmember Replacement»(/saturn/sky/i-final-2010-2010/remont/frames-subframes-crossmembers/#frame-underbody) .
  16. Remove the stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(/saturn/sky/i-final-2010-2010/remont/suspension-rear/#rear-suspension-system) .
  17. Position an adjustable jack under the fuel tank.
  18. Remove the fuel tank strap/support bolts (2).
  19. Remove the fuel tank support bolts (3).
  20. Remove the fuel tank supports (1).
  21. Remove the adjustable jack from under the fuel tank and with the aid of an assistant, tilt the tank down towards the left side of the vehicle and carefully remove the tank.
  22. Place the fuel tank onto a suitable work surface.
  23. Cap or plug the fuel feed and EVAP lines in order to prevent fuel loss and/or system contamination.
  24. If the fuel tank is being replaced, perform the following: Disconnect and remove the EVAP line (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) . Remove the EVAP canister. Refer to «Evaporative Emission Canister Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) . Remove the fuel pump module. Refer to «Fuel Pump Module Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. If the fuel tank was replaced, perform the following: Install the fuel pump module. Refer to «Fuel Pump Module Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) . Install the EVAP canister. Refer to «Evaporative Emission Canister Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) . Install and connect the EVAP line (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Remove the caps or plugs from the fuel feed and EVAP lines.
  3. With the aid of an assistant tilt the tank up and carefully install the tank in from the left side of the vehicle.
  4. Position an adjustable jack under the fuel tank.
  5. Position the fuel tank supports (1).
  6. Install the fuel tank strap/support bolts (2) and tighten to 22 N.m (16 lb ft).
  7. Install the fuel tank support bolts (3) and tighten to 22 N.m (16 lb ft).
  8. Remove adjustable jack from under the fuel tank.
  9. Install the stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(/saturn/sky/i-final-2010-2010/remont/suspension-rear/#rear-suspension-system) .
  10. Install the rear suspension crossmember. Refer to «Rear Suspension Support Crossmember Replacement»(/saturn/sky/i-final-2010-2010/remont/frames-subframes-crossmembers/#frame-underbody) .
  11. Install the fuel tank fill EVAP line in through the access hole.
  12. Connect the fuel tank fill pipe EVAP line quick connect fitting (1) to the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  13. Install the fuel fill pipe. Refer to «Fuel Tank Filler Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  14. Unsecure the fuel feed and EVAP purge lines and position to the module.
  15. Connect the EVAP canister purge line quick connect fitting (2) to the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  16. Connect the fuel pump fuel feed line quick connect fitting (1) to the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  17. Connect the EVAP canister vent solenoid electrical connector (2).
  18. Connect the fuel tank pressure sensor electrical connector (5).
  19. Connect the fuel sending unit electrical connector (3).
  20. Install the pump module access cover.
  21. Install the fuel pump module access cover bolts and tighten to 10 N.m (89 lb in).
  22. Install the rear compartment trim panel. Refer to «Rear Compartment Trim Panel Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#interior-trim-system-paneling) .
  23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
  24. Inspect for leaks using the following procedures: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
CAUTIONCap 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.
  1. Remove the rear compartment trim panel. Refer to «Rear Compartment Trim Panel Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#interior-trim-system-paneling) .
  2. Remove the fuel pump module access cover bolts.
  3. Remove the access cover.
  4. Disconnect the fuel tank pressure sensor electrical connector (5).
  5. Remove the fuel tank pressure sensor (2).
  1. Install the fuel tank pressure sensor (2).
  2. Connect the fuel tank pressure sensor electrical connector (5).
  3. Install the fuel pump module access cover.
  4. Install the access cover bolts and tighten to 10 N.m (89 lb in).
  5. Install the rear compartment trim panel. Refer to «Rear Compartment Trim Panel Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#interior-trim-system-paneling) .
  1. Remove the fuel pump module. Refer to «Fuel Pump Module Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Using two flat bladed tools, carefully pull both locking tabs (1) outward while simultaneously lifting the level sensor.
  3. Using a small bladed tool, push in the electrical terminals (1) while simultaneously pulling out.
  1. Push in the electrical terminals (1). Ensure that the electrical terminals attach to the outside holes.
  2. Gently tug on the wires to ensure that the terminals are seated and locked into position.
  3. Carefully insert the level sensor until the locking tabs (1) snap into the locked position.
  4. Ensure that the level sensor wires are not pinched between the module and sensor.
  5. Install the fuel pump module. Refer to «Fuel Pump Module Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

J 45722 Fuel Sender Lock Ring Wrench. See Special Tools .

WARNINGIn 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.
CAUTIONCap 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.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) . Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Remove the rear compartment trim panel. Refer to «Rear Compartment Trim Panel Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#interior-trim-system-paneling) .
  3. Remove the fuel pump module access cover bolts.
  4. Remove the access cover.
  5. Disconnect the fuel sender electrical connector (3).
  6. Disconnect the fuel pressure sensor electrical connector (5).
  7. Disconnect the fuel fill pipe evaporative emission (EVAP) pipe quick connect fitting (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  8. Disconnect the fuel feed pipe quick connect fitting (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  9. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) . Turn the fuel sender lock ring in a counterclockwise direction.
  10. Raise the fuel sender up slightly.
  11. Connect the large EVAP canister quick connect fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  12. Remove the fuel sender assembly.
  13. Remove and discard the fuel sender O-ring.
  14. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gauge at 7 points.
  15. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  16. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
  1. Install a NEW fuel sender O-ring.
  2. Install the fuel sender assembly.
  3. Using the J 45722 , rotate the fuel sender assembly lock ring clockwise until the ring is locked into place on the fuel tank. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
  4. Connect the large EVAP canister quick connect fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  5. Connect the fuel feed pipe quick connect fitting (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  6. Connect the fuel fill pipe EVAP pipe quick connect fitting (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  7. Connect the fuel pressure sensor electrical connector (5).
  8. Connect the fuel sender electrical connector (3).
  9. Install the access cover.
  10. Install the fuel pump module access cover bolts and tighten to 10 N.m (89 lb in).
  11. Install the rear compartment trim panel. Refer to «Rear Compartment Trim Panel Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#interior-trim-system-paneling) .
  12. Refill the tank.
  13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system)
  14. 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.
CAUTIONCap 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.
  1. Remove the rear compartment trim panel. Refer to «Rear Compartment Trim Panel Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#interior-trim-system-paneling) .
  2. Remove the fuel pump module access cover bolts.
  3. Remove the fuel pump module access cover.
  4. Remove the fuel fill pipe housing bolts.
  5. Remove the fuel fill pipe housing.
  6. Remove the rear wheelhouse liner. Refer to «Rear Wheelhouse Panel Liner Replacement»(/saturn/sky/i-final-2010-2010/remont/frames-subframes-crossmembers/#frame-underbody) .
  7. Remove the fill pipe ground strap bolt (2).
  8. Disconnect the fuel tank fill evaporative emission (EVAP) line quick connect fitting (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  9. Loosen the fuel fill pipe hose clamp (1) at the fuel tank.
  10. Separate and remove the fuel fill pipe hose assembly.
  11. Cover or plug the fuel tank opening and the EVAP line in order to prevent fuel loss and/or system contamination.
  1. Remove the cover and/or plug from the fuel tank opening and the EVAP line.
  2. Install the fuel fill pipe hose assembly.
  3. Tighten the fuel fill pipe hose clamp (1) at the fuel tank to 4.5 N.m (40 lb in).
  4. Connect the fuel tank fill EVAP line quick connect fitting (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  5. Install the fill pipe ground strap bolt (2) and tighten to 9 N.m (80 lb in).
  6. Install the rear wheelhouse liner. Refer to «Rear Wheelhouse Panel Liner Replacement»(/saturn/sky/i-final-2010-2010/remont/frames-subframes-crossmembers/#frame-underbody) .
  7. Install the fuel fill pipe housing.
  8. Install the fuel fill pipe housing bolts and tighten to 1.5 N.m (13 lb in).
  9. Install the pump module access cover.
  10. Install the fuel pump module access cover bolts and tighten to 10 N.m (89 lb in).
  11. Install the rear compartment trim panel. Refer to «Rear Compartment Trim Panel Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/exteriorinterior-trim/#interior-trim-system-paneling) .
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  3. Disconnect the evaporative emission (EVAP) pipe (2) quick connect fitting from the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  4. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  5. Cap or plug the fuel feed pipe, fuel rail and EVAP line to in order to system prevent contamination.
  6. Remove the fuel feed and evaporative emission (EVAP) pipe clip from the coolant tube bracket.
  7. Ensure that the area around the brake pipe connections is free of dirt and/or debris.
  8. Remove the brake pipes from the brake pressure modulator valve (BPMV), if equipped.
  9. Remove the brake pipes from the proportioning valve, if equipped.
  10. Cap or plug the BPMV or the proportioning valve in order to prevent system contamination.
  11. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  12. Remove the brake hose clips (2) from both the right and left brake hose brackets.
  13. Remove the right and left brake pipes (1) from the brake hoses.
  14. Remove the pipe clips (1) from the following: Rear suspension lower control arm bracket Left side brace floor panel tunnel
  15. Remove the pipe clips (1) from the following: Floor panel number 4 cross bar Rear carrier bracket Right side brace floor panel tunnel
  16. Remove the pipe clip (2) from the floor panel rear reinforcement.
  17. Have an assistant support the fuel feed, EVAP, and brake pipe assembly.
  18. Remove the pipe clip (1) from the underbody side rail.
  19. Remove the pipe clip (2) from the floor panel tunnel brace stud.
  20. Remove the pipe clip (3) from the floor panel tunnel brace stud.
  21. Remove the pipe clips (4) from the floor panel studs.
  22. Remove the fuel feed, EVAP, and brake pipe assembly from the vehicle and place on a suitable work surface.
  23. Disconnect the fuel pump fuel feed line (5) from the fuel feed line. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  24. Remove the retaining clip (1) from the lines.
  25. Open the clips (4 and 7), and remove the fuel feed line (2) from the clips.
  26. Inspect and replace and damaged clips.
  1. Install the fuel feed line (2) to the clips and close the clips (4 and 7).
  2. Install the retaining clip (1) to the lines.
  3. Connect the fuel pump fuel feed line (5) to the fuel feed line. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  4. With the aid of an assistant, install the fuel feed, EVAP, and brake pipe assembly to the vehicle.
  5. Install the pipe clips (4) to the floor panel studs.
  6. Install the pipe clip (3) to the floor panel tunnel brace stud.
  7. Install the pipe clip (2) to the floor panel tunnel brace stud.
  8. Install the pipe clip (1) to the underbody side rail.
  9. Install the pipe clip (2) to the floor panel rear reinforcement.
  10. Install the pipe clips (1) from the following: Floor panel number 4 cross bar Rear carrier bracket Right side brace floor panel tunnel
  11. Install the pipe clips (1) to the following: Rear suspension lower control arm bracket Left side brace floor panel tunnel
  12. Install the right and left brake pipes (1) to the brake hoses.
  13. Install the brake hose clips (2) to both the right and left brake hose brackets.
  14. Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  15. Remove the cap or plug from the BPMV or the proportioning valve.
  16. Install the brake pipes to the proportioning valve, if equipped, and tighten to 20 N.m (15 lb ft).
  17. Install the brake pipes to the BPMV, if equipped and tighten to 20 N.m (15 lb ft).
  18. Install the fuel feed and EVAP pipe clip to the coolant tube bracket.
  19. Remove the cap or plug from the fuel feed pipe, fuel rail and EVAP line.
  20. Connect the fuel feed pipe (1) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  21. Connect the EVAP pipe (2) to the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
  23. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the fuel pump fuel feed line quick connect fitting (2) from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Remove the fuel pump fuel feed line.
  1. Install the fuel pump fuel feed line.
  2. Connect the fuel pump fuel feed line quick connect fitting (2) to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

Fuel System Cleaning

IMPORTANTIf the fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Remove the fuel pump module assembly. Refer to «Fuel Pump Module Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Inspect the fuel pump module strainer. Replace the pump module assembly if the fuel strainer is contaminated.
  4. Flush the fuel tank with hot water.
  5. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete.
  6. Allow the tank to dry completely before reassembly.
  7. Disconnect the fuel feed pipe at the engine fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  8. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow.
  9. Connect the fuel feed pipe to the engine fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  10. Install the fuel pump module assembly. Refer to «Fuel Pump Module Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  11. Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Relieve the low side fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Disconnect the fuel feed line quick connect fitting (1) from the fuel feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Loosen the fuel feed pipe fitting to the high pressure fuel pump.
  4. Remove the fuel feed pipe bolts.
  5. Remove the fuel feed pipe from the intake manifold. Discard the pipe.
  1. Ensure that the fuel feed pipe and fuel pump fittings are clean prior to assembly.
  2. Lubricate the fuel feed pipe and the high pressure fuel pump fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  3. Position the NEW fuel feed pipe onto the intake manifold.
  4. Install the fuel feed pipe fitting to the high pressure fuel pump hand tight.
  5. Install the fuel feed pipe bolts. Tighten the bolts to 10 N.m (89 lb in). Tighten the fitting to 30 N.m (22 lb ft).
  6. Connect the fuel feed line quick connect fitting (1) to the fuel feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  7. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  8. Install the low side fuel pressure service port cap.
  9. Tighten the fuel fill cap.
  1. Remove the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
  2. Remove the air inlet screen support nuts and support.
  3. Relieve the high side fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  4. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  5. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
  6. Remove the high pressure fuel pump cover bolts.
  7. Remove the high pressure fuel pump cover.
  8. Remove the high pressure fuel pump insulator.
  9. Loosen the high pressure fuel pipe fitting at the fuel pump.
  10. Loosen the high pressure fuel pipe fitting at the fuel rail.
  11. Remove and discard the high pressure fuel pipe.
  1. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  2. Install the NEW high pressure fuel pipe.
  3. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight.
  4. Tighten the NEW high pressure fuel pipe fitting to the high pressure fuel pump hand tight to 32 N.m (24 lb ft).
  5. Install the high pressure fuel pump insulator.
  6. Position the high pressure fuel pump cover.
  7. Install the high pressure fuel pump cover bolts and tighten to 10 N.m (89 lb in).
  8. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  9. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.
  10. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  11. Install the low side fuel pressure service port cap.
  12. Tighten the fuel fill cap.
  13. Install the air inlet screen support and nuts and tighten to 10 N.m (89 lb in).
  14. Install the air inlet grille panel. Refer to «Air Inlet Grille Panel Replacement (SKY)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) or «Air Inlet Grille Panel Replacement (Solstice)»(/saturn/sky/i-final-2010-2010/remont/wiperwasher-systems/#wiper-system-washer-system) .
  1. J 2619-01 Slide Hammer. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
  2. J-37281-A Injector Remover. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-special-tools-and-equipment) .
  1. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
  2. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle) .
  3. Remove the fuel injector insulator.
  4. Relieve the high side fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  6. Remove the high pressure fuel pump cover bolts.
  7. Remove the high pressure fuel pump cover.
  8. Remove the engine wiring harness clip from the high pressure fuel pump cover.
  9. Remove the high pressure fuel pump insulator.
  10. Loosen the high pressure fuel pipe fitting at the fuel pump.
  11. Loosen the high pressure fuel pipe fitting at the fuel rail.
  12. Remove and discard the high pressure fuel pipe.
  13. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  14. Remove the fuel rail bolts (1).
  15. Carefully remove the fuel rail (2). Remove the fuel injector hold-down clamp before removing the fuel injector. NOTE: Use the injector remover and slide hammer to pull the fuel injector straight out along the fuel injector axis. DO NOT tilt or twist the fuel injector during this process. Use J-37281-A: injector remover, and J 2619-01: hammer to remove the fuel injector. Once injectors have been removed it will be necessary to clean and rebuild all the injectors. Refer to «Fuel Rail and Injectors Cleaning and Inspection»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle-1-of-2) .
  16. If replacing the fuel rail, remove the fuel injection fuel rail fuel pressure sensor.
  17. Remove the fuel injector wiring harness.
  1. If the fuel rail was replaced, lubricate the threads and sealing cone of the NEW fuel rail with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  2. Lubricate the threads and sealing cone of the sensor with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  3. Install the fuel injection fuel rail fuel pressure sensor and tighten to 33 N.m (25 lb ft).
  4. Install the fuel injector wiring harness.
  5. Place the fuel rail (2) into position.
  6. 9. Install the fuel rail with injectors into the cylinder head evenly.
  7. Install the 2 outer fuel rail bolts (1) first hand tight, and then install the remaining 2 bolts, hand tight.
  8. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
  9. Tighten the fuel rail bolts in the sequence shown. Tighten the bolts a first pass to 22 N.m (16 lb ft). Tighten the bolts a final pass to 22 N.m (16 lb ft).
  10. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  11. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  12. Install a NEW high pressure fuel pipe.
  13. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight.
  14. Tighten the NEW high pressure fuel pipe fitting to the fuel pump hand tight to 32 N.m (24 lb ft).
  15. Install the high pressure fuel pump insulator.
  16. Install the engine wiring harness clip to the high pressure fuel pump cover.
  17. Install the high pressure fuel pump cover.
  18. Install the high pressure fuel pump cover bolts and tighten to 10 N.m (89 lb in).
  19. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  20. Install the fuel injector insulator.
  21. Install the intake manifold. Refer to «Intake Manifold Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle) .
  22. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  23. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  24. Install the low side fuel pressure service port cap.
  25. Tighten the fuel fill cap.
  1. Relieve the high side fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Disconnect the fuel injector wiring harness electrical connector (1) from the fuel injection fuel rail fuel pressure sensor.
  3. Insert a 27 mm socket through the opening in the foam insulator (2) onto the fuel injection fuel rail fuel pressure sensor (1).
  4. Place a clean shop towel under the fuel injection fuel rail pressure sensor to fuel rail location.
  5. Remove and discard the fuel injection fuel rail fuel pressure sensor (1).
  6. Allow any fuel to drain from the fuel rail and pressure sensor location.
  7. Dry the sealing cone in the fuel rail and the area around the sensor joint with a lint free cloth.
  8. Inspect the sealing cone in the fuel rail. The surface should be free of fuel, debris, and burrs.
  1. Lubricate the threads and the sealing cone in the fuel rail with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  2. Lubricate the threads and sealing cone on the NEW fuel injection fuel rail fuel pressure sensor with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  3. Install the NEW fuel injection fuel rail fuel pressure sensor hand tight.
  4. Remove the NEW fuel injection fuel rail fuel pressure sensor, re-lubricate following steps 1 and 2 above.
  5. Install the NEW fuel injection fuel rail fuel pressure sensor (1) and tighten to 33 N.m (25 lb ft).
  6. Connect the fuel injector wiring harness electrical connector (1) to the fuel injection fuel rail fuel pressure sensor.
  7. Install a NEW high pressure fuel line. Refer to «Fuel Feed Intermediate Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  8. Install the low side fuel pressure service port cap.
  9. Tighten the fuel fill cap.
  10. Inspect for fuel leaks using the following procedure: Place a sheet of paper towel in between the bottom of the sensor and the top of the generator. Start the vehicle and allow the vehicle to idle for approximately 5 minutes. Shut the vehicle off. Remove the paper towel and inspect the towel for wetting. If wetting is noted repeat steps 1 through 5.
  1. Relieve the low and high side fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  3. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
  4. Remove the high pressure fuel pump cover bolts.
  5. Remove the high pressure fuel pump cover.
  6. Remove the high pressure fuel pump insulator.
  7. Loosen the fuel feed pipe to fuel pump fitting.
  8. Remove the fuel feed pipe bolts.
  9. Remove the fuel feed pipe from the intake manifold.
  10. Loosen the high pressure fuel pipe fitting at the fuel pump.
  11. Loosen the high pressure fuel pipe fitting at the fuel rail.
  12. Remove and discard the high pressure fuel pipe.
  13. Remove and discard the high pressure fuel pump bolts.
  14. Remove the high pressure fuel pump.
  15. Remove and discard the high pressure fuel pump gasket.
  16. Remove and discard the high pressure fuel pump O-ring.
  17. Remove the high pressure fuel pump roller lifter, if necessary.
  1. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  2. Install the high pressure fuel pump roller lifter, if necessary.
  3. Install a NEW high pressure fuel pump O-ring.
  4. Position the NEW high pressure fuel pump gasket to the cylinder head.
  5. Install the high pressure fuel pump. Push the pump into the cylinder head bore by hand, applying force to the top of the pump.
  6. Install the NEW high pressure fuel pump bolts hand tight.
  7. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  8. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  9. Install the NEW high pressure fuel pipe.
  10. Tighten the high pressure fuel pipe fitting to the fuel rail hand tight.
  11. Tighten the high pressure fuel pipe fitting to the fuel pump hand tight.
  12. Place the fuel feed pipe onto the intake manifold.
  13. Install the fuel feed pipe bolts hand tight.
  14. Tighten the fuel feed pipe to fuel pump fitting hand tight. Tighten the fuel feed pipe bolts to 10 N.m (89 lb in). Tighten the fuel feed pipe to fuel pump fitting to 30 N.m (22 lb ft). Tighten the high pressure fuel pipe fittings to 32 N.m (24 lb ft). Tighten the high pressure fuel pump bolts evenly to 15 N.m (11 lb ft).
  15. Install the high pressure fuel pump insulator.
  16. Position the high pressure fuel pump cover.
  17. Install the high pressure fuel pump cover bolts and tighten to 10 N.m (89 lb in).
  18. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  19. Install the engine wiring harness clip (3) to the fuel pump cover.
  20. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  21. Install the low side fuel pressure service port cap.
  22. Tighten the fuel fill cap.
  1. J-2619-01: Slide Hammer
  2. J-37281-A: Injector Remover
  1. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
  2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Remove the fuel injector insulator.
  4. Relieve the high side fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  6. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
  7. Remove the high pressure fuel pump cover bolts.
  8. Remove the high pressure fuel pump cover.
  9. Remove the high pressure fuel pump insulator.
  10. Loosen the high pressure fuel pipe fitting at the fuel pump.
  11. Loosen the high pressure fuel pipe fitting at the fuel rail.
  12. Remove and discard the high pressure fuel pipe.
  13. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  14. Remove the fuel rail bolts (1).
  15. Carefully remove the fuel rail (2).
  16. Remove and discard the direct fuel injector hold down clamps.
  17. Remove the direct fuel injectors. Remove the fuel injector hold-down clamp before removing the fuel injector. NOTE: Use the injector remover and slide hammer to pull the fuel injector straight out along the fuel injector axis. DO NOT tilt or twist the fuel injector during this process. Use J-37281-A: injector remover, and J-2619-01: hammer to remove the fuel injector. Once injectors have been removed it will be necessary to clean and rebuild all the injectors. Refer to «Fuel Rail and Injectors Cleaning and Inspection»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-off-vehicle-1-of-2) .
  18. Remove the fuel injector.
  1. Install the 2 outer fuel rail bolts (1) first, hand tight and install the remaining 2 bolts, hand tight.
  2. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
  3. Tighten the fuel rail bolts in the sequence shown. Tighten the bolts a first pass to 22 N.m (16 lb ft). Tighten the bolts a final pass to 22 N.m (16 lb ft).
  4. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  5. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  6. Install the NEW high pressure fuel pipe.
  7. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight.
  8. Tighten the NEW high pressure fuel pipe fitting to the fuel pump hand tight to 32 N.m (24 lb ft).
  9. Install the high pressure fuel pump insulator.
  10. Install the high pressure fuel pump cover.
  11. Install the high pressure fuel pump cover bolts and tighten to 10 N.m (89 lb in).
  12. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  13. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.
  14. Install the fuel injector insulator.
  15. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  16. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  17. Install the low side fuel pressure service port cap.
  18. Tighten the fuel fill cap.
  19. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Low Pressure without Special Tool)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-low-pressure-without) or «Fuel Pressure Relief (Low Pressure with CH 48027)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (Low Pressure Side with CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) or «Fuel Pressure Relief (High Pressure Side)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions__fuel-pressure-relief-high-pressure-side) .
  2. Disconnect the evaporative emission (EVAP) pipe (1) quick connect fitting from the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Disconnect the fuel feed pipe (2) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  4. Cap or plug the fuel feed pipe, fuel rail and EVAP line to in order to system prevent contamination.
  5. Remove the fuel feed and evaporative emission (EVAP) pipe clip from the oil level indicator tube bracket.
  6. Ensure that the area around the brake pipe connections is free of dirt and/or debris.
  7. Remove the brake pipes from the brake pressure modulator valve (BPMV), if equipped.
  8. Remove the brake pipes from the proportioning valve, if equipped.
  9. Cap or plug the BMPV or the proportioning valve in order to prevent system contamination.
  10. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  11. Remove the brake hose clips (2) from both the right and left brake hose brackets.
  12. Remove the right and left brake pipes (1) from the brake hoses. (left side shown, right side similar).
  13. Remove the pipe clips (1) from the following: Rear suspension lower control arm bracket Left hand brace floor panel tunnel
  14. Remove the pipe clips (1) from the following: Floor panel number 4 cross bar Rear carrier bracket Right hand brace floor panel tunnel
  15. Remove the pipe clip (2) from the floor panel rear reinforcement.
  16. Have an assistant support the fuel feed, EVAP, and brake pipe assembly.
  17. Remove the pipe clip (1) from the underbody side rail.
  18. Remove the pipe clip (2) from the floor panel tunnel brace stud.
  19. Remove the pipe clip (3) from the floor panel tunnel brace stud.
  20. Remove the pipe clips (4) from the floor panel studs.
  21. Remove the fuel feed, EVAP, and brake pipe assembly from the vehicle and place on a suitable work surface.
  22. Disconnect the EVAP canister purge line (6) from the EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  23. Remove the retaining clip (1) from the lines.
  24. Open the clips (4 and 7), and remove the EVAP line (3) from the clips.
  25. Inspect and replace and damaged clips.
  1. Install the EVAP line (3) to the clips and close the clips (4 and 7).
  2. Install the retaining clip (1) to the lines.
  3. Connect the EVAP canister purge line (6) to the EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  4. With the aid of an assistant, install the fuel feed, EVAP, and brake pipe assembly to the vehicle.
  5. Install the pipe clips (4) to the floor panel studs.
  6. Install the pipe clip (3) to the floor panel tunnel brace stud.
  7. Install the pipe clip (2) to the floor panel tunnel brace stud.
  8. Install the pipe clip (1) to the underbody side rail.
  9. Install the pipe clip (2) to the floor panel rear reinforcement.
  10. Install the pipe clips (1) from the following: Floor panel number 4 cross bar Rear carrier bracket Right hand brace floor panel tunnel
  11. Install the pipe clips (1) to the following: Rear suspension lower control arm bracket Left hand brace floor panel tunnel
  12. Install the right and left brake pipes (1) to the brake hoses. (left side shown, right side similar).
  13. Install the brake hose clips (2) to both the right and left brake hose brackets.
  14. Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  15. Remove the cap or plug from the BMPV or the proportioning valve.
  16. Install the brake pipes to the proportioning valve, if equipped, and tighten to 20 N.m (15 lb ft).
  17. Install the brake pipes to the BPMV, if equipped, and tighten to 20 N.m (15 lb ft).
  18. Install the fuel feed and EVAP pipe clip to the oil level indicator tube bracket.
  19. Remove the cap or plug from the fuel feed pipe, fuel rail and EVAP line.
  20. Connect the fuel feed pipe (2) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  21. Connect the EVAP pipe (1) to the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
  23. Inspect for fuel leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the evaporative emission (EVAP) line quick connect fitting from the fuel pump module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Disconnect the EVAP line quick connect fitting at the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  4. Disconnect the EVAP line from the roll over valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  5. Cap or plug the EVAP connections, fuel pump module, and canister in order to prevent system contamination.
  6. Disengage the EVAP line from the fuel tank retaining features.
  7. Remove the EVAP line (1) from the fuel tank.
  1. Install the EVAP line (1) to the fuel tank.
  2. Engage the EVAP vapor line to the fuel tank retaining features.
  3. Remove the caps or plugs from the EVAP line connections, fuel pump module, and canister.
  4. Connect the EVAP line quick connect fitting to the roll over valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  5. Connect the EVAP line quick connect fitting at the fuel sender. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  6. Connect the EVAP line quick connect fitting at the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  7. Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the evaporative emission (EVAP) canister purge line quick connect fitting (1) at the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Remove the EVAP canister purge line.
  1. Install the EVAP canister purge line.
  2. Connect the EVAP canister purge line quick connect fitting (1) to the chassis. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Remove the fuel fill pipe. Refer to «Fuel Tank Filler Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the fuel tank fill evaporative emission (EVAP) pipe quick connect fitting (1) at the fuel pump module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Remove the fuel tank fill EVAP pipe.
  1. Install the fuel tank fill EVAP pipe.
  2. Connect the fuel tank fill EVAP pipe quick connect fitting (1) to the fuel pump module. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Install the fuel fill pipe. Refer to «Fuel Tank Filler Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (2) from the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
  3. Remove the EVAP canister purge solenoid bolt (6).
  4. Remove the EVAP canister purge solenoid (5).
  5. Remove the EVAP canister purge solenoid O-ring seal (4), if necessary.
  6. Inspect for carbon release in the EVAP canister purge solenoid ports. If there is any loose carbon, replace the EVAP canister and any components necessary to remove the carbon particles.
  1. Install the EVAP canister purge solenoid O-ring seal (4) to the solenoid, if necessary.
  2. Lubricate the O-ring seal with clean engine oil.
  3. Install the EVAP canister purge solenoid to the intake manifold.
  4. Install the EVAP canister purge solenoid bolt and tighten to 10 N.m (89 lb in).
  5. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
  6. Connect the chassis EVAP line quick connect fitting (2) to the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the evaporative emission (EVAP) canister vent solenoid valve tube quick connect fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Depress the locking tab on the EVAP canister vent solenoid valve mount and slide the valve out of the canister.
  1. Install the EVAP canister vent solenoid valve onto the mount on the canister, push the valve forward until the locking tab engages.
  2. Connect the EVAP canister vent tube quick connect fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Remove the evaporative emission (EVAP) canister/fuel tank line. Refer to «Evaporative Emission Line Replacement - Canister to Tank»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Slide the EVAP canister upward from the bracket.
  1. Slide the NEW EVAP canister down into the bracket.
  2. Install the EVAP canister/fuel tank line. Refer to «Evaporative Emission Line Replacement - Canister to Tank»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

J 41413 EVAP Pressure and Purge Station

Inspection Procedure

  1. Turn OFF the ignition.
  2. Remove the EVAP canister purge solenoid. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Lightly tap the EVAP canister purge valve on a hard surface.
  4. Inspect for carbon particles exiting either of the vacuum ports. If no carbon particles were detected, but a blockage was detected during a diagnostic procedure, install the original EVAP canister purge valve. Continue with the cleaning procedure. If carbon particles are found during the inspection procedure, continue with the cleaning procedure. If a diagnostic procedure directed you to replace the EVAP canister purge valve and no carbon particles were detected, replace the EVAP canister purge valve. Return to the published service procedure.

Cleaning Procedure

  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/saturn/sky/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
  2. Remove the EVAP canister. Refer to «Evaporative Emission Canister Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Turn OFF the main valve on the J 41413 .
  4. Disconnect the hose from the diagnostic station pressure regulator.
  5. Using a section of vacuum hose, connect one end onto the EVAP pressure/purge diagnostic station pressure regulator.
  6. Connect the other end of the vacuum hose to the canister side of the purge pipe.
  7. Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.
  8. If the nitrogen does not clear the blockage, replace the purge pipe.
  9. Return the EVAP pressure/purge diagnostic station to the stations original condition.
  10. Install a new EVAP canister. Refer to «Evaporative Emission Canister Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  11. Lower the vehicle.
  12. Install a new EVAP canister purge solenoid. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  13. Return to the diagnostic table that sent you here.
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the ignition coil electrical connector(s).
  3. Remove the ignition coil bolt(s).
  4. Remove the ignition coil(s).
  1. Install the ignition coil(s).
  2. Install the ignition coil bolt(s) and tighten to 10 N.m (89 lb in).
  3. Connect the ignition coil electrical connector(s).
  4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

Spark Plug Usage

  1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-specifications__ignition-system-specifications) for the correct spark plug.
  2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug Pre-ignition causing spark plug and/or engine damage-Hotter plug

Spark Plug Inspection

  1. Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.
  2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
  3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
  4. Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-specifications__ignition-system-specifications) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-specifications__ignition-system-specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. Inspect for excessive fouling.
  5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

  1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
  2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
  3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode.
  1. Remove the ignition coil(s). Refer to «Ignition Coil Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Remove the spark plugs using a 5/8 inch spark plug socket.
  1. Install the spark plugs and tighten to 20 N.m (15 lb ft). Specification: The spark plug gap is 0.90 mm (0.035 in).
  2. Apply dielectric compound to the spark plug boots and make sure no corrosion is present.
  3. Install the ignition coil(s). Refer to «Ignition Coil Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Remove the starter. Refer to «Starter Replacement»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
  2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
  3. Remove the CKP sensor bolt.
  4. Remove the CKP sensor.
  1. Lubricate the CKP sensor O-ring seal with clean engine oil.
  2. Install the CKP sensor. CAUTION: Refer to «Fastener Caution»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
  3. Install the CKP sensor bolt and tighten to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
  5. Install the starter. Refer to «Starter Replacement»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
  1. Remove the fuel feed intermediate pipe. Refer to «Fuel Feed Intermediate Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the engine wiring harness electrical connector (2) from the intake camshaft position (CMP) sensor.
  3. Remove the CMP sensor bolt.
  4. Remove the CMP sensor.
  1. Lubricate the CMP sensor O-ring seal with clean engine oil.
  2. Install the CMP sensor. CAUTION: Refer to «Fastener Caution»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
  3. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (2) to the intake CMP sensor.
  5. Install the fuel feed intermediate pipe. Refer to «Fuel Feed Intermediate Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Disconnect the engine wiring harness electrical connector (4) from the exhaust camshaft position (CMP) sensor.
  2. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar)
  3. Remove the CMP sensor.
  1. Lubricate the CMP sensor O-ring seal with clean engine oil.
  2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar) CAUTION: Refer to «Fastener Caution»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
  3. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (4) to the exhaust CMP sensor.
  1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Disconnect the engine wiring harness electrical connector from either the intake (2) or exhaust (1) camshaft position actuator solenoid valve, as required.
  3. Remove the exhaust (1) camshaft position actuator solenoid valve bolt and valve, as required.
  4. Remove the intake (2) camshaft position (CMP) actuator solenoid valve bolt and valve, as required.
  5. Inspect the solenoid valve O-ring seals from damage, replace as necessary.
  1. Lubricate the solenoid valve O-ring seals with clean engine oil.
  2. Install the intake (2) CMP actuator solenoid valve and bolt, as required, and tighten to 10 N.m (89 lb in).
  3. Install the exhaust (1) CMP actuator solenoid valve and bolt, as required, and tighten to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector to the intake (1) or exhaust (2) camshaft position actuator solenoid valve, as required.
  5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Disconnect the engine wiring harness electrical connector (2) from the front knock sensor, if required.
  2. Disconnect the engine wiring harness electrical connector (2) from the rear knock sensor, if required.
  3. Remove the front knock sensor clip (1) from the oil level indicator tube, if required.
  4. Remove the rear knock sensor clip (2) from the intake manifold brace, if required.
  5. Loosen the appropriate knock bolt.
  6. Remove the appropriate knock sensor.
  1. Position the appropriate knock sensor to the engine block.
  2. Tighten the appropriate knock bolt to 25 N.m (18 lb ft).
  3. Install the front knock sensor clip (1) to the oil level indicator tube, if required.
  4. Install the rear knock sensor clip (2) to the intake manifold brace, if required.
  5. Connect the engine wiring harness electrical connector (2) to the rear knock sensor.
  6. Connect the engine wiring harness electrical connector (2) to the front knock sensor.
  1. Disconnect the engine wiring harness electrical connector (2) from the intake air pressure and temperature sensor.
  2. Remove the intake air pressure and temperature sensor bolts.
  3. Remove the intake air pressure and temperature sensor.
  1. Lubricate the intake air pressure and temperature sensor O-ring with clean engine oil.
  2. Install the intake air pressure and temperature sensor.
  3. Install the intake air pressure and temperature sensor bolts and tighten to 2.5 N.m (22 lb in).
  4. Connect the engine wiring harness electrical connector (2) to the intake air pressure and temperature sensor.
  1. Disconnect the engine wiring harness electrical connector from the charge air bypass solenoid.
  2. Reposition the charge air bypass solenoid vacuum hose clamp (5) at the turbocharger and remove the hose.
  3. Remove the charge air bypass solenoid vacuum hose from the turbocharger coolant feed hose clamps (4).
  4. Reposition the charge air bypass solenoid vacuum hose clamp (3) at the charge air cooler outlet pipe and remove the hose.
  5. Reposition the charge air bypass solenoid vacuum hose clamp (1) at the intake manifold and remove the hose.
  6. Remove the charge air bypass solenoid bolts (2).
  7. Remove the charge air bypass solenoid.
  1. Position the charge air bypass solenoid to the engine.
  2. Install the charge air bypass solenoid bolts (2) and tighten to 10 N.m (89 lb in).
  3. Install the charge air bypass solenoid vacuum hose to the intake manifold and position the clamp (1).
  4. Install the charge air bypass solenoid vacuum hose to the charge air cooler outlet pipe and position the clamp (3).
  5. Install the charge air bypass solenoid vacuum hose to the turbocharger coolant feed hose clamps (4).
  6. Install the charge air bypass solenoid vacuum to from the turbocharger and install the clamp (5).
  7. Connect the engine wiring harness electrical connector to the charge air bypass solenoid.

Scheme 5

Scheme 5: Charge Air Bypass Valve Replacement
Scheme 5: Charge Air Bypass Valve Replacement
CalloutComponent Name
Preliminary Procedure: Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Charge Air Bypass Bolt CAUTION: Refer to Fastener Caution . Procedure: Disconnect the vacuum hose. Tighten: 10 N.m (89 lb in)
2Charge Air Bypass Valve
3Charge Air Bypass Valve Diaphragm Spring
4Charge Air Bypass Valve Diaphragm
CAUTION
Refer to Fastener Caution .

Scheme 6

Scheme 6: Turbocharger Wastegate Actuator Replacement
Scheme 6: Turbocharger Wastegate Actuator Replacement
CalloutComponent Name
Preliminary Procedure: Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Wastegate Actuator Bolt CAUTION: Refer to Fastener Caution . Procedure: Disconnect the vacuum hose. Tighten: 10 N.m (89 lb in)
2Turbocharger Wastegate Actuator
CAUTION
Refer to Fastener Caution .

Turbocharger Wastegate Actuator Adjustment

  1. Remove the turbocharger heat shield.
  2. Loosen the lock nut (2).
  3. Hand tighten the lock nut (1) until it is seated on the wastegate arm and slight spring tension is observed.
  4. Mark the lock nut (1) with a paint pen to mark a starting position and tighten three complete turns.
  5. While holding the wastegate rod tighten the nut (2) hand tight.
  6. Tighten the nut (2) while holding nut (1) in place to 10 N.m(89 lb in). Apply GM P/N 12345493 threadlock to the wastegate actuator rod threads on both sides.
  1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.
  2. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing.
  3. Remove the air cleaner outlet duct from the air cleaner housing.
  4. Unlatch the upper air cleaner cover retainer clips.
  5. Remove the upper air cleaner cover.
  6. Remove the air cleaner filter from the lower air cleaner housing.
  7. Inspect the air cleaner filter for dust, dirt, and water contamination. Replace as necessary. Refer to «Maintenance Schedule (North American Emissions)»(/saturn/sky/i-final-2010-2010/remont/lubrication-system/#maintenance-and-lubrication__maintenance-schedule-north-american-emissions) .
  1. Install the NEW air cleaner filter into the lower air cleaner housing.
  2. Install the upper air cleaner cover to the lower air cleaner housing.
  3. Latch the upper air cleaner cover retainer clips.
  4. Install the air cleaner outlet duct to the air cleaner housing.
  5. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing to 4 N.m (35 lb in).
  6. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
  1. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Remove the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  4. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.
  5. Remove the air cleaner assembly front bolt.
  6. Firmly tug on the air cleaner lower assembly in order to disengage the air cleaner from the studs.
  7. Remove the air cleaner assembly from the vehicle.
  1. Install the air cleaner assembly to the vehicle.
  2. Position the air cleaner assembly over the studs. Firmly press down over the studs in order to engage the air cleaner to the studs.
  3. Install the air cleaner assembly front bolt and tighten to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (1) to the MAF sensor.
  5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  6. Install the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  7. Install the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  1. Disconnect the positive crankcase ventilation (PCV) tube from the air cleaner outlet duct.
  2. Loosen the air cleaner outlet duct clamp (1) at the air cleaner housing.
  3. Loosen the air cleaner outlet duct clamp (2) at the turbocharger.
  4. Remove the air cleaner outlet duct.
  1. Install the air cleaner outlet duct.
  2. Tighten the air cleaner outlet duct clamp (2) at the turbocharger.
  3. Tighten the air cleaner outlet duct clamp (1) at the air cleaner housing to 4 N.m (35 lb in).
  4. Connect the PCV tube to the air cleaner outlet duct.
  1. Remove the hood. Refer to «Hood Replacement»(/saturn/sky/i-final-2010-2010/remont/exterior-body-panels/#bolted-exterior-body-panels-closures) .
  2. Remove the horn. Refer to «Horn Replacement»(/saturn/sky/i-final-2010-2010/remont/horns/#horn-system) .
  3. Remove the charge air cooler inlet pipe bolt (3) at the rear bracket.
  4. Remove the charge air cooler rear bracket nut (2) and bracket (1).
  5. Remove the charge air cooler inlet pipe bolt (1) at the front bracket.
  6. Loosen the charge air cooler clamp (2) at the charge air cooler inlet pipe.
  7. Loosen the charge air cooler inlet pipe clamp (4) at the charge air cooler pipe.
  8. Remove the charge air cooler inlet pipe.
  9. Remove any oil film from inside the pipes.
  1. Install the charge air cooler inlet pipe to the charge air cooler pipe and the charge air cooler.
  2. Install the charge air cooler rear bracket (1) and nut (2). Tighten the nut to 9 N.m (80 lb in).
  3. Install the charge air cooler inlet pipe bolt (3) at the rear bracket and tighten to 7 N.m (62 lb in).
  4. Install the charge air cooler inlet pipe bolt (1) at the front bracket and tighten to 7 N.m (62 lb in).
  5. Tighten the charge air cooler clamp (2) at the charge air cooler pipe.
  6. Tighten the charge air cooler inlet pipe clamp (4) at the charge air cooler pipe to 5 N.m (44 lb in).
  7. Install the horn. Refer to «Horn Replacement»(/saturn/sky/i-final-2010-2010/remont/horns/#horn-system) .
  8. Install the hood. Refer to «Hood Replacement»(/saturn/sky/i-final-2010-2010/remont/exterior-body-panels/#bolted-exterior-body-panels-closures) .
  1. Loosen the charge air cooler hose clamp (1) at the throttle body.
  2. Loosen the charge air cooler hose clamp (2) at the charge air cooler outlet pipe.
  3. Remove the charge air cooler hose from the throttle body and the outlet pipe.
  1. Install the charge air cooler hose to the outlet pipe and the throttle body.
  2. Tighten the charge air cooler hose clamp (2) at the charge air cooler outlet pipe.
  3. Tighten the charge air cooler hose clamp (1) at the throttle body. Tighten: Tighten the charge air cooler hose clamps to 5 N.m (44 lb in).
  1. Disconnect the engine wiring harness electrical connector (2) from the intake air pressure and temperature sensor.
  2. Reposition the charge air bypass valve solenoid vacuum hose clamp (3) at the charge air cooler outlet pipe.
  3. Remove the vacuum hose from the charge air cooler outlet pipe.
  4. Remove the charge air cooler outlet pipe bolt (1) at the rear bracket.
  5. Remove the charge air cooler rear bracket nut (4) and bracket (1).
  6. Loosen the charge air cooler hose clamp (2) at the throttle body charge air cooler outlet hose.
  7. Remove the charge air cooler outlet pipe from the throttle body charge air cooler hose (1).
  8. If needed, remove the throttle body charge air cooler hose (1) from the throttle body.
  9. Remove the charge air cooler outlet pipe bolt (3) at the front bracket.
  10. Loosen the charge air cooler clamp (2) at the charge air cooler outlet pipe.
  11. Remove the charge air cooler outlet pipe.
  12. Remove any oil film from inside the pipes and hoses.
  1. Install the charge air cooler outlet pipe to the charge air cooler and the charge air cooler hose.
  2. Install the charge air cooler outlet pipe bolt (3) at the front bracket and tighten to 7 N.m (62 lb in).
  3. Install the charge air cooler rear bracket (1) and nut (4). Tighten the nut to 9 N.m (80 lb in).
  4. Install the charge air cooler outlet pipe bolt (1) at the rear bracket and tighten to 7 N.m (62 lb in).
  5. Tighten the charge air cooler clamp (2) at the charge air cooler outlet pipe and tighten to 5 N.m (44 lb in).
  6. If removed, install the throttle body charge air cooler hose (1) onto the throttle body and tighten to 5 N.m (44 lb in).
  7. Install the charge air cooler outlet pipe to the throttle body charge air cooler hose.
  8. Tighten the throttle body charge air cooler hose clamp (2) at the charge air cooler outlet pipe to 5 N.m (44 lb in).
  9. Install the vacuum hose to the charge air cooler outlet pipe.
  10. Position the charge air bypass valve solenoid vacuum hose clamp (3) at the charge air cooler outlet pipe.
  11. Connect the engine wiring harness electrical connector (2) to the intake air pressure and temperature sensor.
  1. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  2. Remove the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  3. Remove the front radiator air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
  4. Remove the front bumper fascia air deflector. Refer to «Front Bumper Fascia Air Deflector Replacement»(/saturn/sky/i-final-2010-2010/remont/exterior-body-panels/#bumpers-and-fascia) .
  5. Remove the charge air cooler bolts.
  6. Remove the charge air cooler.
  1. Install the charge air cooler.
  2. Install the charge air cooler bolts and tighten to 9 N.m (80 lb in).
  3. Install the front bumper fascia air deflector. Refer to «Front Bumper Fascia Air Deflector Replacement»(/saturn/sky/i-final-2010-2010/remont/exterior-body-panels/#bumpers-and-fascia) .
  4. Install the front radiator air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/saturn/sky/i-final-2010-2010/remont/cooling-system-mechanical/#engine-cooling-system) .
  5. Install the charge air cooler outlet pipe. Refer to «Charge Air Cooler Outlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  6. Install the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .

See also:
• Battery Negative Cable Disconnection and Connection
• Front Fender Replacement
• Windshield Washer Solvent Container Replacement (Solstice)
• Control Module References
• Clutch Pedal Position Sensor Learn
• Cooling System Draining and Filling (GE-47716)
• Fastener Caution
• Heated Oxygen Sensor Resistance Learn Reset Caution
• Lifting and Jacking the Vehicle
• Knee Bolster Replacement (SKY)
• Gasoline/Gasoline Vapors Warning
• Special Tools
• Relieving Fuel Pressure Warning
• Fuel Pipe Fitting Warning
• Rear Compartment Trim Panel Replacement (Convertible)
• Rear Suspension Support Crossmember Replacement
• Stabilizer Shaft Replacement
• Intake Manifold Replacement
• Fuel Rail and Injectors Cleaning and Inspection
• Ignition System Specifications
• Maintenance Schedule (North American Emissions)
• Horn Replacement
• Exterior Trim Emblem Removal Caution
• Front Bumper Fascia Air Deflector Replacement
• Charge Air Cooler Outlet Pipe Replacement
• Fuel Pressure Relief (Low Pressure without Special Tool)
• Fuel Pressure Relief (High Pressure Side)

More articles — Engine Performance