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Home >> Saturn >> 2005 >> Relay FWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 3.5L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Replacement (Short Wheel Base) >> Installation Procedure
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Installation Procedure

    Fig 1: Identifying Fuel Tank And Related Components
    GM1544794Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel sender assembly (3). Refer to Fuel Sender Assembly Replacement (Short Wheel Base)  or Fuel Sender Assembly Replacement (Long Wheel Base) .
  2. Install the EVAP pipe assembly.
  3. Install the fuel feed pipe (5).
  4. Install the EVAP canister vent solenoid (2).
  5. Connect the quick-connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  6. Install the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement (Short Wheel Base)  or Evaporative Emission (EVAP) Canister Replacement (Long Wheel Base) .
    7. Fig 2: View Of Fuel Tank
    GM49733Courtesy of GENERAL MOTORS CORP.
  7. With the aid of an assistant, position and support the fuel tank.
  8. Connect the fuel sender and the FTP sensor electrical connectors at the body pass through.
    9. Fig 3: Locating Fuel Tank Strap Attaching Bolts
    GM49727Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install the fuel tank retaining strap attaching bolts.

    Tighten:  Tighten the fuel tank retaining strap bolts to 47.5 N.m (35 lb ft).

  10. Install the fuel tank shield.
    11. Fig 4: Locating Vapor Recirculation Pipe At Filler Tube
    GM49730Courtesy of GENERAL MOTORS CORP.
  11. Connect the vapor recirculation pipe to the fuel fill pipe.
    12. Fig 5: View Of Fuel Tank Filler Pipe At Fuel Tank
    GM49720Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel tank filler pipe to the fuel tank.

    Tighten:  Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).

    13. Fig 6: Identifying Fuel Tank And Related Components
    GM1544794Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel feed pipe (5) quick-connect fitting. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  14. Connect the EVAP purge pipe (6) quick-connect fitting at the EVAP canister. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  15. Lower the vehicle.
    16. Fig 7: Locating Fuel Tank Filler Pipe Cap
    GM49725Courtesy of GENERAL MOTORS CORP.
  16. Add fuel.
  17. Install the fuel tank filler pipe cap.
  18. Connect the negative battery cable.
  19. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
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