Engine Controls and Fuel - 2.4l - Repair Instructions Saturn Sky I final

Engine Control Module Replacement

Note. It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change.

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. Disconnect the engine harness electrical connectors (2) from engine control module (ECM).
6. Release the upper retaining tab using a small screwdriver or other suitable tool.
7. Remove the ECM by lifting upward after releasing the tab.

Installation Procedure

1. Slide the ECM into the bracket.
2. Push down on the ECM until the retaining tab snaps into place.
3. Connect the engine harness electrical connectors (2) to the ECM.
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. Reset the clock and preset radio stations.
6. 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) .

Crankshaft Position System Variation Learn

Note. The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: Engine replacement Engine control module (ECM) replacement Crankshaft damper replacement Crankshaft replacement CKP sensor replacement Any engine repairs which disturb the crankshaft to CKP sensor relationship

Note. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensor activity - If there is a CKP sensor condition, refer to the applicable DTC that set. Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC that set. Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.

1. Install a scan tool.
2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
3. With a scan tool, select the CKP system variation learn procedure and perform the following: Observe the fuel cut-off for the applicable engine. Block the drive wheels. Set the parking brake. Place the vehicle's transmission in Park or Neutral. Turn the air conditioning (A/C) OFF. Cycle the ignition from OFF to ON. Apply and hold the brake pedal for the duration of the procedure. Start and idle the engine. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. NOTE: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. Release the throttle when fuel cut-off occurs.
4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to «DTC P0315»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-dtc-p0010-to-dtc-p0366) . If any other DTCs set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully.

Description

The engine control module (ECM) learns the idle position of the throttle plate to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned.

A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero.

The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.

Conditions for Running the Throttle Learn Procedure

1. DTCs P0101, P0102, P0103, P0107, P0108, P0111, P0112, P0113, P0506, and P0507 are not set.
2. The engine speed is between 450-4,000 RPM.
3. The manifold absolute pressure (MAP) is greater than 5 kPa.
4. The mass air flow (MAF) is greater than 2 g/s.
5. The ignition 1 voltage is greater than 10 volts.

With Scan Tool-Reset

1. Ignition ON, engine OFF. With a scan tool, perform the Idle Learn Reset in Module Setup.
2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation parameter value should equal 0 percent and the engine should be idling at a normal idle speed. If the engine is not idling normally, proceed with the Learn portion of the diagnostic.
3. Clear the DTCs and return to the diagnostic that referred you here.

Without Scan Tool-Learn

1. The engine speed is between 450-4,000 RPM.
2. The manifold absolute pressure (MAP) is greater than 5 kPa.
3. The mass air flow (MAF) is greater than 2 g/s.
4. The ignition 1 voltage is greater than 10 volts.
5. Start and idle the engine in Park for 3 minutes.
6. With a scan tool, monitor desired and actual RPM.
7. The ECM will start to learn the new idle cells and Desired RPM should start to decrease.
8. Ignition OFF for 60 seconds.
9. Start and idle the engine in Park for 3 minutes.
10. After the 3 minute run time the engine should be idling normal. If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles.
11. After the drive cycle, the engine should be idling normally. If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6.
12. Once the engine speed has returned to normal, clear DTCs.

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. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
3. Remove the ECT.

1. Install the ECT. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
2. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
3. 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 mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1).
2. Remove the MAF/IAT sensor screws.
3. Remove the MAF/IAT sensor.

1. Install the MAF/IAT sensor.
2. Install the MAF/IAT sensor screws. Tighten: Tighten the screws to 0.6 N.m (5 lb in).
3. Connect the MAF/IAT sensor electrical connector (1).

1. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
3. Remove the MAP sensor and the MAP sensor port seal if it is still retained in the intake manifold

1. Install the MAP sensor with the port seal into the intake manifold
2. Connect the MAP sensor electrical connector.
3. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

Special Tools

J 39194 Oxygen Sensor Wrench

Note. The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the heated oxygen sensor (HO2S).

Note. The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F).

1. Open the hood.
2. Remove the connector position assurance (CPA) retainer.
3. Disconnect the HO2S electrical connector (2).
4. Remove the HO2S electrical connector clip from the junction block bracket.
5. Using the J 39194 , remove the HO2S (1).

Note. A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation.

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 HO2S (1). Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Install the HO2S electrical connector clip to the junction block bracket.
4. Connect the HO2S electrical connector (2).
5. Install the CPA retainer.
6. Close the hood.

J 39194 Oxygen Sensor Wrench

Note. The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the heated oxygen sensor (HO2S).

Note. The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F).

1. Open the hood.
2. Remove the connector position assurance (CPA) retainer.
3. Disconnect the HO2S electrical connector (3).
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 HO2S (2).

Note. A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation.

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 HO2S (2). Tighten: Tighten the HO2S to 41 N.m (30 lb ft).
3. Lower the vehicle.
4. Connect the HO2S electrical connector (3).
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 intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the air cleaner outlet. Refer to «Air Cleaner Outlet Resonator Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Disconnect the electronic throttle control (ETC) electrical connector (3).
4. Remove the throttle body bolts.
5. Remove the throttle body from the intake manifold.

1. Inspect the throttle body gasket and replace if necessary.
2. Position the throttle body to the intake manifold. CAUTION: Refer to «Fastener Caution»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
3. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
4. Connect the ETC electrical connector (3).
5. Install the air cleaner outlet. Refer to «Air Cleaner Outlet Resonator Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
6. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
7. Perform the throttle learn procedure. Refer to «Throttle/Idle Learn»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

Throttle Body Cleaning

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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 ACDelco Carburetor Tune-up Conditioner P/N X66-P, or an equivalent product.
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
5. Perform the throttle/idle learn procedure. Refer to «Throttle/Idle Learn»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

CH-48027-100 Digital Pressure Gauge

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 rail service port cap.
4. Wrap a shop towel around the fuel rail service port.
5. Connect the CH-48027-3 (3) to the fuel rail 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 rail 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 rail service port cap.
15. Install the engine cover, if required.
16. Tighten the fuel fill cap.

Fuel Pressure Relief (Without CH 48027-100)

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 rail service port cap.
4. Wrap a shop towel around the fuel rail 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 rail service port, and place in an approved gasoline container.
6. Install the fuel rail service port cap.
7. Install the engine cover, if required.
8. Tighten the fuel fill cap.

CH-48027 Digital Pressure Gauge

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
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.

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.

CH-48027-100 Digital Pressure Gauge

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
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.

J 37088-A Fuel Line Disconnect Tool Set

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
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 (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
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
2. J 42960-2 Fuel Flapper Door Holder
3. J 45004 Fuel Tank Drain Hose

Fuel Tank 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.
3. Insert the J 45004 into the fuel tank until the hose reaches the bottom of the fuel tank.
4. Use a hand or air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
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-24l-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-24l-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-24l-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-24l-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-24l-repair-instructions) . Remove the EVAP canister. Refer to «Evaporative Emission Canister Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Evaporative Emission Canister Replacement (Coupe)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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-24l-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-24l-repair-instructions) . Install the EVAP canister. Refer to «Evaporative Emission Canister Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Evaporative Emission Canister Replacement (Coupe)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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-24l-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-24l-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-24l-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-24l-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-24l-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.

Fuel System Cleaning

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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-24l-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-24l-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-24l-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-24l-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-24l-repair-instructions) .

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-24l-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) and ensure the terminals are secure.
2. Carefully insert the level sensor until the locking tabs (1) snap into the locking position.
3. Install the fuel pump module. Refer to «Fuel Pump Module Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

J 45722 Fuel Sender Lock Ring Wrench

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
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 sending unit 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-24l-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-24l-repair-instructions) .
9. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. 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-24l-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.
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-24l-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-24l-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-24l-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 sending unit access cover bolts.
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.

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-24l-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. Install the fuel fill pipe hose clamp (1) at the fuel tank and tighten to 2.5 N.m (22 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-24l-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. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
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-24l-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-24l-repair-instructions) .
4. Cap or plug the fuel feed pipe, fuel rail and EVAP line in order to prevent system 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-24l-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.
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 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-24l-repair-instructions) .
23. Remove the retaining clip (1) from the lines.
24. Open the clips (4 and 7), and remove the fuel feed line (2) from the clips.
25. Inspect and replace and damaged clips.

1. Install the fuel feed line (2) to the clips and close the clips (4, 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-24l-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. Tighten: Tighten the pipes to 20 N.m (15 lb ft).
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-24l-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. Tighten: Tighten the pipes to 20 N.m (15 lb ft).
17. Install the brake pipes to the BPMV, if equipped. Tighten: Tighten the pipes 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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-repair-instructions) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
2. Disconnect the fuel feed line quick connect fitting 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-24l-repair-instructions) .
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
4. Disconnect the fuel injector inline electrical connector (1).
5. Disconnect the electronic throttle control (ETC) electrical connector (3).
6. Remove the 2 engine harness clips (2, 5) from the fuel rail tabs.
7. Remove the fuel rail bolts (1).
8. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports.
9. Remove the fuel rail.
10. Remove the fuel injectors, if necessary. Refer to «Fuel Injector Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
11. If the fuel injectors are also being replaced, remove the fuel injector insulators (2).

1. Install the fuel injectors, if necessary. Refer to «Fuel Injector Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. If new fuel injectors are being used, lubricate the NEW fuel injector insulators (2) with clean engine oil and install them to the cylinder head.
3. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
4. Carefully push the fuel injectors into the cylinder head ports. CAUTION: Refer to «Fastener Caution»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
5. Install the fuel rail bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
6. Install the 2 engine harness clips (2, 5) to the fuel rail tabs.
7. Connect the ETC electrical connector (3).
8. Connect the fuel injector inline electrical connector (1).
9. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
10. Connect the fuel feed line quick connect fitting 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-24l-repair-instructions) .
11. 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) .
12. 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. Inspect for fuel leaks.

Note. If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel.

1. Remove the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the fuel injector retaining clip (1).
3. Remove the fuel injector (3) from the fuel rail.
4. Remove the fuel injector upper O-ring (2).
5. Remove the fuel injector lower O-ring (4).

1. The fuel injector assembly (1) is stamped with a part number identification (2).
2. Lubricate the new injector O-rings (2, 4) with clean engine oil.
3. Install the fuel injector upper O-ring (2).
4. Install the fuel injector lower O-ring (4).
5. Install the fuel injector (3) to the fuel rail.
6. Install the fuel injector retaining clip (1).
7. Install the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

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. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector (1).
3. Disconnect the EVAP canister purge valve tube. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
4. Disconnect the chassis EVAP vapor line from the EVAP canister purge valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
5. Remove the EVAP canister purge valve bracket bolt.
6. Remove the EVAP canister purge valve with bracket.
7. Remove the EVAP canister purge valve from the bracket.
8. Inspect for carbon release in the EVAP canister purge valve 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 valve to the bracket.
2. Position the EVAP canister purge valve with bracket to the cylinder head. CAUTION: Refer to «Fastener Caution»(/saturn/sky/i-final-2010-2010/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
3. Install the EVAP canister purge valve bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
4. Connect the EVAP canister purge valve tube. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
5. Connect the chassis EVAP vapor line to the EVAP canister purge valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
6. Connect the EVAP canister purge valve electrical connector (1).
7. 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. If convertible, remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) . If coupe, remove the carbon canister. Refer to «Evaporative Emission Canister Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Evaporative Emission Canister Replacement (Coupe)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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-24l-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-24l-repair-instructions) .
3. If convertible, Install the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) . If coupe, install the carbon canister. Refer to «Evaporative Emission Canister Replacement (Convertible)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Evaporative Emission Canister Replacement (Coupe)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions)

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Disconnect the evaporative emission (EVAP) canister purge valve tube from the EVAP canister purge solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
4. Disconnect the EVAP canister purge valve tube from the intake manifold purge port. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
5. Remove the EVAP canister purge valve tube.

1. Install the EVAP canister purge valve tube.
2. Connect the EVAP canister purge valve tube to the intake manifold purge port. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Connect the EVAP canister purge valve tube to the EVAP canister purge solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

Scheme 1

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-repair-instructions) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Fuel Pressure Relief (Without CH 48027-100)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) .
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-24l-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-24l-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-24l-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.
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-24l-repair-instructions) .
23. Remove the retaining clip (1) from the lines.
24. Open the clips (4, 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, 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-24l-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. Tighten: Tighten the pipes to 20 N.m (15 lb ft).
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-24l-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. Tighten: Tighten the pipes to 20 N.m (15 lb ft).
17. Install the brake pipes to the BPMV, if equipped. Tighten: Tighten the pipes 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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-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-24l-repair-instructions) .
2. Remove the evaporative emission (EVAP) canister/fuel tank line. Refer to «Evaporative Emission Line Replacement - Canister to Tank (Convertible)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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 (Convertible)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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-24l-repair-instructions) .

Scheme 2

J 41413 EVAP Pressure and Purge Station

Inspection Procedure

1. Turn OFF the ignition.
2. Remove the EVAP canister purge valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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 (Convertible)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Evaporative Emission Canister Replacement (Coupe)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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 (Convertible)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) or «Evaporative Emission Canister Replacement (Coupe)»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
11. Lower the vehicle.
12. Install a new EVAP canister purge valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
13. Return to the diagnostic table that sent you here.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
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). Tighten: Tighten the bolt(s) to 10 N.m (89 lb in).
3. Connect the ignition coil electrical connector(s).
4. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. Remove the ignition coil(s). Refer to «Ignition Coil Replacement»(/saturn/sky/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the spark plugs using a 5/8 inch spark plug socket.

1. Install the spark plugs. Specification: The spark plug gap is 1.0 mm (0.040 in). Tighten: Tighten the plugs to 20 N.m (15 lb ft).
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-24l-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-24l-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-24l-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-24l-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 starter. Refer to «Starter Replacement»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the crankshaft position (CKP) sensor electrical connector (1).
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. Tighten: Tighten the sensor bolt to 10 N.m (89 lb in).
4. Connect the CKP sensor electrical connector (1).
5. Install the starter. Refer to «Starter Replacement»(/saturn/sky/i-final-2010-2010/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the intake camshaft position (CMP) sensor electrical connector.
2. Remove the CMP sensor bolt.
3. 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. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Connect the intake CMP sensor electrical connector.

1. Disconnect the exhaust camshaft position (CMP) sensor electrical connector (1).
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. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Connect the exhaust CMP sensor electrical connector (1).

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Disconnect the intake (1) or exhaust (2) camshaft position actuator solenoid valve electrical connector, 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. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Install the exhaust (1) CMP actuator solenoid valve and bolt, as required. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Connect the intake (1) or exhaust (2) camshaft position actuator solenoid valve electrical connector, as required.
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/saturn/sky/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. Disconnect the knock sensor (KS) electrical connector (3).
2. Remove the KS electrical connector clip from the oil level indicator tube bracket.
3. Remove the KS bolt.
4. Remove the KS.

Note. Rotate the pigtail 90 degrees from vertical before securing the fastener.

1. Install the KS.
2. Install the KS bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
3. Disconnect the KS electrical connector (3).
4. Install the KS electrical connector clip to the oil level indicator tube bracket.

1. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1).
2. Unlatch the upper air cleaner cover retainer clips.
3. Remove the upper air cleaner cover.
4. Remove the air cleaner filter from the lower air cleaner housing.
5. Inspect the air cleaner filter for dust, dirt and water contamination.
6. 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 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. Connect the MAF/IAT sensor electrical connector (1).

Scheme 3

Scheme 4

See also:
• Battery Negative Cable Disconnection and Connection
• Control Module References
• Diagnostic Trouble Code (DTC) List - Vehicle
• DTC P0315
• 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)
• Intake Manifold Cover Replacement
• Gasoline/Gasoline Vapors Warning
• Relieving Fuel Pressure Warning
• Fuel Pipe Fitting Warning
• Fuel Tank Draining (Non E-85)
• Rear Compartment Trim Panel Replacement (Convertible)
• Rear Suspension Support Crossmember Replacement
• Stabilizer Shaft Replacement
• Air Inlet Grille Panel Replacement (SKY)
• Ignition System Specifications
• Maintenance Schedule (North American Emissions)
• Throttle Body Assembly Replacement
• Fuel Pressure Relief (Without CH 48027-100)