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Home >> Saturn >> 2005 >> Vue Red Line, AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 3.5L (L66) 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 the 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: 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.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Remove the rubber exhaust hangers on order to allow the exhaust system to drop slightly.
    Fig 1: Identifying Exhaust Muffler Hangers
    GM892074Courtesy of GENERAL MOTORS CORP.
  6. Remove the propeller shaft, if equipped. Refer to Propeller Shaft Replacement in Propeller Shaft.
    7. NOTE: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.
    Fig 2: View Of Evaporative Emission Canister
    GM1226407Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the EVAP canister vent and fresh air hoses:
    1. Grasping both sides of the quick-connect fitting, twist the female connector 1/4 turn in each direction in order to loosen dirt within the quick-connect fitting.
    2. Blow any dirt out of the quick-connect fitting using compressed air.
    3. Squeeze the plastic retainer release tabs.
    4. Pull the connection apart.
    5. Inspect both ends of the quick-connect fitting for dirt and burrs.
  8. Remove the fuel filler pipe, EVAP vent hose, and fresh air hose from the fuel tank.
    Fig 3: View Of Fuel Filler Pipe, EVAP Vent & Fresh Air Hoses At Fuel Tank
    GM1347586Courtesy of GENERAL MOTORS CORP.
    9. 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 chassis fuel supply line from the tank.
  10. Disconnect the electrical connectors:
    1. Fuel tank electrical connectors
    2. EVAP solenoid electrical connector
    11. NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.
    IMPORTANT: Do not disassemble the RDM. It is not necessary to touch the RDM for fuel tank removal.
  11. Support the fuel tank.
  12. Remove the fuel tank strap bolts and fuel tank straps.
    Fig 4: View Of Fuel Tank Heat Shield & Fuel Tank Assembly Into The Vehicle
    GM927748Courtesy of GENERAL MOTORS CORP.
  13. Lower the fuel tank from the underbody of the vehicle.
  14. Remove the fuel tank module assemblies. Refer to Fuel Tank Module Replacement - Primary  and Fuel Tank Module Replacement - Secondary .
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