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Home >> Saturn >> 2002 >> SC2 L4-1.9L DOHC VIN 7 >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Tank >> Service and Repair >> Removal and Replacement

Removal and Replacement

REMOVAL
1. Assure that fuel level in tank is not greater than half. If necessary, drain fuel tank to at least this level (refer to "Fuel Tank Draining").
2. Position on hoist.
3. Disconnect negative battery cable.

CAUTION: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER THE ENGINE IS SHUT DOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM.




4. Relieve pressure in fuel system at fuel pressure test port (refer to "Relieving Fuel Pressure").




5. Remove fuel filler cap and rubber closeout grommet around fuel filler pipe neck (inside fuel filler door).
6. Remove attachment screw (T-30) at upper end of filler pipe.
7. Raise vehicle to a comfortable working position.
8. Remove wheel house inner liner.
9. Disconnect wiring harness connector from EVAP canister vent solenoid.




10. Remove fuel filler pipe lower bracket attachment screw (10 mm hex) at underbody left hand side rail.
11. Disconnect EVAP canister vent pipe at 5/8 in. quick connect to canister vent hose.
12. Loosen fuel filler pipe hose clamp (7 mm hex) closest to the fuel tank.

CAUTION: SEVERAL OUNCES OF GASOLINE MAY REMAIN IN THE FUEL FILLER PIPE DUE TO THE DESIGN OF THE INLET CHECK VALVE. BE AWARE OF THIS WHEN HANDLING THE FILLER PIPE DURING REMOVAL FROM THE FUEL TANK. SURROUND THE CHECK VALVE BODY WITH A SHOP CLOTH HELD IN PLACE WITH YOUR HAND. HAVE A SUITABLE CONTAINER AVAILABLE AND DRAIN ANY FUEL BY UNSEATING THE CHECK VALVE.

NOTE: To provide space to remove filler pipe, guide top of filler pipe into quarter panel opening while removing fuel filler pipe.

13. Disengage filler pipe hose from fuel tank and remove fuel filler pipe.

NOTE:
^ Keep fuel filler pipe as straight and level as possible when removing it from the tank. Fuel fill check valve clamp may drag on the inlet neck of the tank and care should be used in removing it. If valve is dislodged from filler pipe it may remain in the tank.
^ If there is more than 11.51(3 gal.) of fuel in the tank, insert a suitable siphon hose into tank filler neck and remove remaining fuel into a certified fuel handling cart.




14. Remove (2) screws (10 mm hex) that attach fuel filter/pressure regulator bracket to vehicle underbody.

CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR REMOVED, WRAP A SHOP CLOTH AROUND THE FITTING AND HAVE AN APPROVED CONTAINER AVAILABLE TO COLLECT ANY FUEL.

15. Disconnect fuel feed line (90° quick-connect) from outlet of filter/pressure regulator.
16. Disconnect fuel vapor/canister purge line at 90° quick-connect adjacent to fuel filter/pressure regulator.
17. Slide filter/regulator bracket out from under brake lines.
18. With aid of an assistant, remove two tank retaining strap bolts (15 mm hex) and lower tank enough to disconnect the two electrical connectors to the fuel pomp and tank pressure sensor.
19. Remove fuel tank from vehicle.

INSTALLATION




1. With aid of an assistant, position fuel tank under vehicle.
2. Attach electrical connectors to fuel pump and tank pressure sensor.

NOTE: Position the fuel tank solidly against the left hand underbody side rail prior to tightening the strap mounting bolts. A small white locator button on the left side of the fuel tank shell should he tight against the left side rail at the completion of installation.




3. Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts (15 mm hex) to underbody.

Torque:
Fuel Tank Straps-to-Body: 47 N.m (35 ft-lbs)

4. Install (2) mounting screws (10 mm hex) for the fuel filter/pressure regulator bracket.

Torque:
Fuel Filter/Pressure Regulator-to-Frame Rail: 8 N.m (71 in-lbs)

NOTE: Replace the plastic fuel line retainers whenever the fuel supply lines are disconnected at the fuel filter/pressure regulator and fuel rail. Install the new retainer into the female portion of the connection. Care must be taken to assure that the locking tab is centered in the window of the female connection. Firmly press the male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.

5. Install a new retainer into the female portion of the of the 90° quick-connect fitting on the underbody fuel feed line.

IMPORTANT: Lubricate the male ends of the filter/regulator with clean engine oil to ease installation.

6. Install the underbody fuel feed line onto the outlet of filter/regulator.




7. Insure that fuel filler check valve is in place at the end of fuel filler pipe.

IMPORTANT: To ease installation, lightly wipe the outside of the fuel tank inlet connector with plain water.

8. Position filler pipe into wheel opening with top of pipe within body panel opening.
9. Install fuel filler pipe into fuel tank opening.




10. Loosely install filler pipe lower bracket attachment screw (10 mm hex) but do not tighten.

NOTE: Insure that EVAP vent solenoid pipe is installed in position on filler pipe bracket.

11. Lower vehicle and install filler pipe upper bracket attachment screw (T-30).

Torque:
Fuel Tank Fill Pipe-to-Upper Bracket: 4 +/- .5 N.m (35 +/- 4 in-lbs)




12. Install rubber closeout grommet to body and filler pipe.
13. Install fuel cap.
14. Raise vehicle to comfortable working height.

NOTE: Ensure that the fuel pipe connecting hose is installed to within 6 mm (1/4 in.) of the stops on the fuel tank inlet connector. The hose clamp should be located within 4 mm (3/16 in.) of the end of the connecting hose.

15. Tighten hose clamp (7 mm hex) on filler pipe to fuel tank connecting hose.

Torque:
Fuel Tank Fill Hose-to-Clamp: 4 +/- .5 N.m (35 +/- 4 in-lbs)

16. Connect EVAP canister vent pipe at quick connect to canister vent hose.
17. Tighten lower attachment screw on filler pipe to underbody.

Torque:
Fuel Tank Fill Pipe-to-Underbody Rail: 8 N.m (71 in-lbs)

18. Connect wiring harness to EVAP vent solenoid.
19. Install wheelhouse inner liner to wheel opening.
20. Add fuel, install filler cap, and connect negative battery cable.

Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)

21. Prime fuel system using either of the following methods:
^ Using ignition, cycle switch On for five seconds and then Off for 10 seconds. Repeat this twice.
^ Energize the fuel pump using the Scan tool (refer to "Energizing the Fuel Pump"). Run the pump for 10-20 seconds.
22. Examine fuel supply line for leaks at filter/pressure regulator.
23. Crank engine until it starts (allowing a maximum of 15 seconds of cranking time).
24. Perform the "Service Bay Diagnostic Test" for the evaporative emission system using the Scan tool. This test will verify the integrity of the vapor handling areas of the fuel system.
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