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

    CAUTION: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.
  1. Ensure that fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining Procedure .
    2. CAUTION: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
  2. Position the vehicle on the hoist.
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
    4. CAUTION: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.
  4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  5. Raise the vehicle to a comfortable working position.
    6. Fig 1: Disconnecting/Reconnecting Exhaust Resonator From Exhaust Manifold Pipe
    GM891510Courtesy of GENERAL MOTORS CORP.
  6. Remove the exhaust system intermediate pipe with the muffler.
    7. Fig 2: Removing Rear Heat Shield
    GM892450Courtesy of GENERAL MOTORS CORP.
  7. Remove the rear heat shield retaining bolts.
    8. Fig 3: Removing/Installing Fuel Filler Pipe Lower Bracket Attaching Screw
    GM893228Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel filler pipe lower bracket attachment screw.
    9. Fig 4: Disconnecting EVAP Canister Vent Hose & Recirculation Line Quick Connect Fitting
    GM892352Courtesy of GENERAL MOTORS CORP.
    CAUTION: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.
  9. Disconnect the evaporative emission (EVAP) canister vent hose.
  10. Loosen the fuel filler pipe hose clamp closest to the fuel tank.
  11. Disconnect the quick connect at the recirculation line.
    12. IMPORTANT: If there is more than 11.4 liters (3 gallons) of fuel in the tank, insert a suitable siphon hose into the tank filler neck and remove the remaining fuel into a certified fuel handling cart.
  12. Disengage the filler pipe hose from the fuel tank.
    13. Fig 5: Removing/Installing Fuel Line Stone Chip Guard
    GM885839Courtesy of GENERAL MOTORS CORP.
  13. Remove the tank grounding strap attachment nut located near the fuel filter.
  14. Remove the fuel tank strap bracket and fuel line stone chip guard, protecting the fuel line connections between the fuel tank and the chassis fuel bundle.
    15. Fig 6: Identifying Fuel Line Fittings At Fuel Filter & Chassis Fuel Bundle
    GM892344Courtesy of GENERAL MOTORS CORP.
    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 the fuel feed line after the fuel filter.
  16. Disconnect the fuel return and the EVAP canister purge lines between the tank and the chassis fuel bundle.
  17. Disconnect the fuel tank electrical connections.
  18. Loosen the front tank strap bolts, but do not remove.
  19. With the aid of an assistant, remove the 2 rear tank retaining strap bolts.
    1. Lower the rear half of the tank and slide the fuel tank down and out rearward.
    2. Remove the fuel tank from the vehicle.
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