Removal & Install Fuel Tank
WARNING:- Whenever the fuel tank requires removal, the fuel level should not be more than 3/4 full if the fuel tank is more than 3/4 full, use extreme care when removing hoses.
- Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place.
- Anytime the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
DRAINING FUEL TANK - REMOVAL
1. Remove fuel fill cap and position vehicle on a hoist and block wheels.
2. Disconnect negative battery cable at battery.
WARNING: whenever fuel line fittings are loosened or disconnected, wrap a shop towel cloth around fuel lines to collect fuel, then relieving fuel place cloth in an approved container.
Fuel System Pressure Relief:
3. Release fuel pressure at valve using gage bar kit (Saturn Tool) SA9127E located on fuel delivery line to engine and install cap.
WARNING: Make sure the vehicle is properly supported and squarely positioned on hoist. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist. Make sure hoist does not contact fuel or brake lines.
Lifting Rear Of Vehicle With Jack:
4. Raise rear of vehicle approximately 28 inches to a comfortable working position. This allows the fuel to flow forward in the tank away from the fill hose opening.
WARNING: Never drain or store fuel in an open contemner due to the possibility of fire or explosion.
WARNING: Whenever fuel tank fill neck hose is removed, catch fuel in an approved contemner. the container opening must be a minimum of 300 mm (12 in.) diameter to adequately catch the fluid.
Fuel Tank Fill And Vent Hoses:
5. Position an approved drain container with enough capacity to hold the fuel under the fill neck. Loosen the fuel filler neck connecting tube clamp at rear of tank. Wrap a shop towel around fuel filler neck connecting tube and slowly remove fuel filler neck connecting tube from fuel tank.
NOTE: Clean fuel filler neck at tank and surrounding area before disconnecting filler neck tube to avoid possible contamination of the fuel system.
6. Position a siphon hose into the fuel tank through the fuel filler opening. Place other end into an approved container with enough capacity to hold fuel in tank. Siphon fuel from tank.
7. Remove fill neck bracket fastener at left-hand side rear rail. Loosen fuel vent hose clamp at tank.
NOTE: It is easier to remove the hoses off the tank than to pull them off the steel vent and fill tubes.
NOTE: Do not attempt to repair sections of nylon fuel line. If damaged, replace.
Fuel Tank Lines:
8. Disengage the fuel supply and return line connectors by pinching the two plastic tangs together and pulling to separate. Separate the rubber vent line connection by grasping tank assembly line and pushing away rubber connector using a small open end wrench.
WARNING: Use extreme care when removing the fuel tank because it retains approximately four liters (one gallon) of fuel.
NOTE: Do not bend fuel tank retaining straps during tank removal because this may damage them.
Fuel Tank Removal & Installation:
9. With the aid of an assistant, remove the two support strap fasteners at rear of tank and lower fuel tank with support panel approximately eight inches to disconnect the electrical connection at top of tank.
10. Remove the fuel tank from vehicle.
INSTALLATION
1. With the aid of an assistant, position the fuel tank under vehicle. Attach the electrical connector.
2. Install the two fuel tank retaining straps and support panel. install the two rear attaching bolts.
Torque to 47 N.m (35 ft-lbs)
NOTE: To prevent driver's side quarter panel deflection, the fill neck and fuel tank must be properly aligned during installation.
NOTE: The steel band clamps used on fuel lines are designed to prevent hose damage and must be replaced only with original equipment (O.E.) parts.
WARNING: Whenever fuel lines are disconnected at connectors, lubricate the male line ends with clean engine oil. Holding male end of the line, firmly press on female coupler until a click is heard, then pull back to confirm engagement. Pinched, kinked or damaged fuel lines must be replaced.
Fuel Neck Installation:
3. Attach the fuel fill and vent hose and install clamps. Align fill neck and tank. Install fill neck tube and bracket fastener. Insert vent lines into rubber boot until white marks on tube align with side of boot.
- Clamps Torque to 3 N.m (27 in-lbs)
- Fill Neck Bracket Torque to 6 N.m (53 in-lbs)
4. Apply a few drops of clean engine oil to the male connector tube ends. Push connectors together to cause the retaining tabs to lock in place. Once installed, pull on both ends of each connection to make sure it is secure.
5. Lower vehicle hoist. Add fuel, install filler cap and connect battery negative terminal.
6. Prime fuel system.
a. Cycle ignition on for 5 seconds and then off for 10 seconds.
b. Repeat step 8a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat steps 8a-8c.
7. Run engine and check fuel system for leaks.
NOTE: It may be necessary to turn the ignition switch on and off several times to prime the fuel system.