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Home >> Saturn >> 2004 >> Ion Red Line >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls (Introduction) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

  1. If fuel tank replacement was necessary, install the fuel pump module assembly to the fuel tank. Refer to Fuel Pump Module Replacement .
  2. Have an assistant support the fuel tank during fuel tank and fuel tank strap installation.
  3. Begin to install the LH side of the fuel tank over the exhaust pipe.
  4. Raise the RH side of the fuel tank into position inboard of the RH frame rail. Use care in feeding the fuel feed and return pipes, the EVAP vapor pipe, and the fuel pump module electrical harness over the rear axle.
  5. Install the RH fuel tank strap and strap bolts.
  6. Install the LH fuel tank strap and strap bolts.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Tighten the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    8. Fig 1: View Of Fuel Tank Strap Bolts
    GM890002Courtesy of GENERAL MOTORS CORP.
  8. Raise the exhaust into position and install the muffler insulators to the underbody hanger.
    9. Fig 2: View Of Muffler Insulator
    GM1382235Courtesy of GENERAL MOTORS CORP.
  9. Install the exhaust extension pipe insulators to the underbody hangers.
  10. Connect the fuel pump module harness electrical connector to the vehicle underbody connector.
    11. Fig 3: Locating Fuel Pump Module Harness Electrical Connector
    GM889730Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel filler hose to the fuel tank.
    12. NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
  12. Tighten the fuel filler hose clamp (1) at the fuel tank.

    Tighten:  Tighten the clamp to 4.5 N.m (40 lb in).

    13. Fig 4: Fuel Filler Pipe Jumper Hose
    GM889977Courtesy of GENERAL MOTORS CORP.
  13. Remove the caps or plugs from the EVAP purge and vapor pipes.
  14. Connect the EVAP purge pipe (2) and vapor pipe (3) to the EVAP canister. Refer to Quick Connect Fitting(s) Service (Plastic Collar) (Press Release) .
    15. Fig 5: View Of EVAP Pipes
    GM889726Courtesy of GENERAL MOTORS CORP.
  15. Remove the caps or plugs from the fuel tank feed and return pipes.
  16. Connect the fuel feed and return lines to the fuel filter.
  17. Lower the vehicle.
  18. Refill the fuel tank.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  20. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
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