2016 Chevrolet Volt PremierFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: Fuel Tank Fuel Pump Module And Seal
    GM4091065Courtesy of GENERAL MOTORS COMPANY
  1. Install a NEW fuel pump module seal (2).
    2. NOTE:

    Pay attention to the fuel level sensor.

  2. Install Fuel Tank Fuel Pump Module (1)
    3. Fig 2: Fuel Pump Module And Vent Valve Connector
    GM4091064Courtesy of GENERAL MOTORS COMPANY
  3. Connect the vent valve connector (2). Refer to Plastic Collar Quick Connect Fitting Service .
    4. Fig 3: Fuel Pump Module Lock Ring And Wrench
    GM4091063Courtesy of GENERAL MOTORS COMPANY
  4. Install the fuel pump module lock ring (2).
  5. Install the CH-45722  wrench (1) to the fuel pump module lock ring (2).
    6. NOTE:

    DO NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

  6. Using the CH-45722  wrench (1) and a long breaker bar, rotate the lock ring in a clockwise direction in order to lock the lock ring.
  7. Remove the CH-45722  wrench (1).
    8. Fig 4: Fuel Pump Feed Hose, Evaporative Emission Canister Hose, Evaporative Emission Rear Hose, Electrical Connector, Fuel Pump Module Wiring Harness And Retainers
    GM4091018Courtesy of GENERAL MOTORS COMPANY
  8. Connect the electrical connector (6).
  9. Install Evaporative Emission Rear Hose (3). Refer to Plastic Collar Quick Connect Fitting Service 
  10. Install the evaporative emission canister hose (1). Refer to Plastic Collar Quick Connect Fitting Service .
  11. Install Fuel Pump Fuel Feed Hose (8). Refer to Plastic Collar Quick Connect Fitting Service 
  12. Install Retainers (2, 5, 7)
  13. Install Fuel Tank. Refer to Fuel Tank Replacement 
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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