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High Pressure Lock-Off Solenoid: Installation

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Natural gas is stored under high pressure. If a leak occurs, the high pressure could cause a personal injury. To prevent Compressed Natural Gas (CNG) fuel leaks, always replace the CNG fuel system "O" rings during service.
  1. Install the new "O" ring on the HPL.
  2. Lubricate the "O" ring with petroleum jelly.
  3. Ensure that the "O" ring mating surface of the tank is clean and free of debris or damage.
  4. Install the HPL. Tighten the HPL to specification. See TORQUE SPECIFICATIONS .
  5. Install the HPL fill line fitting (4) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. The fill line fitting has the larger thread diameter to accept the fill line. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
  6. Install the HPL outlet fitting (8) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
  7. Install the HPL PRD line fitting (6) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
  8. Ensure that the lines are properly oriented to the HPL fittings. It may be necessary to rotate the CNG tank in the mounting brackets to obtain the proper alignment. See FUEL TANK  for the steps necessary to loosen the tank straps and rotate the tank.
  9. Connect the fuel outlet line to the HPL fitting (1) with a NEW "O" ring face seal. Lubricate the "O" ring face seal using petroleum jelly, or equivalent. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
  10. Install the Fuel Tank Pressure (FTP) sensor (2) with a NEW "O" ring. Lubricate the "O" ring with petroleum jelly, or equivalent. Tighten the sensor to specification. See TORQUE SPECIFICATIONS .
  11. Connect the PRD line to the HPL fitting (4) with a NEW "O" ring face seal. Lubricate the "O" ring face seal using petroleum jelly, or equivalent. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
  12. Install the HPL harness connector stand-offs. Tighten the stand-offs to specification. See TORQUE SPECIFICATIONS .
  13. Connect the fill line to the HPL fitting with a NEW "O" ring face seal. Lubricate the "O" ring face seal using petroleum jelly, or equivalent. Tighten the fitting to specification. See TORQUE SPECIFICATIONS .
  14. Connect the HPL and the FTP sensor harness connectors.
  15. Begin to fill the fuel tank and with the Combustible Gas Detector (J 45878) check the HPL "O" ring for leaks at each of the following pressures:
    • 500 psi (3447 kPa)
    • 1500 psi (10342 kPa)
    • 3000 psi (20684 kPa)
  16. Connect the negative battery cable. Tighten to specification. See TORQUE SPECIFICATIONS .
  17. Start the engine and use the Combustible Gas Detector to check for CNG fuel system leaks at each serviced fitting.
  18. Install the tank vent boot cover and nuts. Tighten the nuts to specification. See TORQUE SPECIFICATIONS .
  19. Install the fuel tank cover. Tighten the fuel tank cover nuts to specification. See TORQUE SPECIFICATIONS .


  1. Install the PRD and the HPL to the HPR lines and the vent hose as an assembly. See Figure.
  2. Connect the PRD and the HPL to HPR lines using new "O" ring face seals. Lubricate the "O" rings with petroleum jelly, or equivalent. Tighten the PRD line fitting and the HPL to the HPR fuel line fittings to specification. See TORQUE SPECIFICATIONS .
  3. Connect the 3 harness connectors.
  4. Connect the negative battery cable. Tighten to specification. See TORQUE SPECIFICATIONS .
  5. Start the engine. Check for CNG fuel leaks at each serviced fitting using the Combustible Gas Detector (J 45878), or equivalent.
  6. Position the vent hose clamps. Tighten the vent hose clamps to specification. See TORQUE SPECIFICATIONS .
  7. Install the valve boot cover and the cover nuts. Tighten the valve boot cover nuts to specification. See TORQUE SPECIFICATIONS .
  8. Raise the rear seat.
  9. Install the spare tire bracket and the spare tire bracket bolts. Tighten the spare tire bracket bolts to specification. See TORQUE SPECIFICATIONS .
  10. Install the fuel tank cover. Tighten the fuel tank cover nuts to specification. See TORQUE SPECIFICATIONS .
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