LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Saturn >> 2003 >> LW200 >> Repair and Diagnosis >> Engine Performance >> Remove, Overhaul & Install >> Engine Controls - Removal & Installation >> Fuel Systems >> Fuel Tank >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Fuel Tank: Installation

  1. With aid of an assistant, position fuel tank with heat shield and straps under vehicle. Attach electrical connectors to fuel pump and tank pressure sensor. Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts to underbody. Tighten fuel tank mounting strap bolts to specification. See TORQUE SPECIFICATIONS  .
    2. CAUTION: Replace plastic fuel line retainers whenever fuel supply lines are disconnected. Install new retainer into female portion of connection. Care must be taken to ensure that locking tab is centered in window of female connection. Firmly press male and female portions together until a click noise is heard, then pull firmly back to confirm engagement.
  2. Install a new retainers into female portion of quick-connect fitting on underbody fuel and EVAP canister purge lines. Lubricate male ends of filter with clean engine oil to ease installation. Connect fuel feed, return and vapor lines. Install fuel tank grounding strap attachment nut located near fuel filler neck.
  3. Tighten the fuel tank grounding strap attachment to specification. Ensure the EVAP vent solenoid pipe is installed in position on filler pipe bracket. Loosely install filler pipe lower bracket attachment screw but do not tighten. Install fill neck to fuel tank. Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body.
  4. The hose clamp should be located within 1/4" of the end of the connector hose. Tighten hose clamp on filler pipe to fuel tank connecting hose to specification. Connect EVAP canister vent pipe at quick-connect to canister vent hose. Tighten lower attachment screw on filler pipe-to-underbody to specification.
  5. Install rear heat shield. Tighten rear heat shield bolts to specification. Install fuel line stone chip guard. Tighten the fuel line stone chip guard fasteners to specification. Install intermediate pipe (with muffler). Add fuel to fuel tank.
  6. Connect negative battery cable. Tighten negative battery terminal bolt to specification. Using ignition, cycle switch On for 5 seconds and then Off for 10 seconds. Repeat this twice. Examine fuel lines for leaks. Crank engine until it starts (allowing a maximum of 20 seconds of cranking time).
scientia non olet · About LEMON Manuals