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Home >> Saturn >> 2005 >> L300 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Positioning Fuel Tank, Heat Shield & Straps Under Vehicle
    GM892354Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, position the fuel tank with the heat shield and straps under the vehicle.
  2. Attach the electrical connectors to the fuel pump and the tank pressure sensor.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Reposition the fuel tank mounting straps and shield around the tank and install the strap mounting bolts to the underbody.

    Tighten:  Tighten the fuel tank mounting strap to 20 N.m (15 lb ft).

    4. NOTE: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.
  4. Install new retainers into the female portion of the quick-connect fitting on the underbody fuel and EVAP canister purge lines.
    5. IMPORTANT: Lubricate the male ends of the filter with clean engine oil to ease installation.
  5. Connect the fuel feed, return, and vapor lines.
  6. Install the fuel tank grounding strap attachment nut located near the fuel filler neck.

    Tighten:  Tighten the fuel tank grounding strap attachment to 4.5 N.m (35 lb in).

    7. Fig 2: Removing/Installing Fuel Filler Pipe Lower Bracket Attaching Screw
    GM893228Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the EVAP vent solenoid pipe is installed in position on the filler pipe bracket.
  7. Loosely install the filler pipe lower bracket attachment screw but do not tighten.
    8. Fig 3: Proper Installation Of Fuel Tank Filler Pipe & Hose Clamp
    GM893316Courtesy of GENERAL MOTORS CORP.
  8. Install the fill neck to the fuel tank.
    9. IMPORTANT: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6 mm (1/4 in) of the end of the connector hose.
  9. Tighten the hose clamp on the filler pipe to fuel tank connecting hose.

    Tighten:  Tighten the fuel fill neck-to-fuel tank clamp to 5 N.m (44 lb in).

    10. Fig 4: Connecting EVAP Canister Vent Hose & Recirculation Line Quick Connect Fitting
    GM892767Courtesy of GENERAL MOTORS CORP.
  10. Connect the EVAP canister vent pipe at the quick connect to canister vent hose.
  11. Tighten the lower attachment screw on the filler pipe to underbody.

    Tighten:  Tighten the fuel fill pipe-to-body (lower) to 13 N.m (9.5 lb ft).

  12. Install the heat shield.

    Tighten:  Tighten the rear heat shield to 8 N.m (71 lb in).

    13. Fig 5: Removing/Installing Fuel Line Stone Chip Guard
    GM885839Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel line stone chip guard.

    Tighten:  Tighten the fuel line stone chip guard to 12 N.m (106 lb in).

    14. Fig 6: Disconnecting/Reconnecting Exhaust Resonator From Exhaust Manifold Pipe
    GM891510Courtesy of GENERAL MOTORS CORP.
  14. Install the intermediate pipe with the muffler.
  15. Add fuel and connect the negative battery cable.

    Tighten:  Tighten the battery terminal bolts to 17 N.m (13 lb ft).

  16. Prime the fuel system.
    • Using the ignition, cycle the switch ON for 5 seconds and then OFF for 10 seconds. Repeat this twice.
    • Examine the fuel lines for leaks.
    • Crank the engine until it starts, allowing a maximum of 20 seconds of cranking time.
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