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Home >> Saturn >> 2010 >> Sky Base, Standard >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 2.4L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
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Removal Procedure

CAUTION: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
    Fig 1: View Of Fuel Pump Module Unit Access Cover
    GM1594369Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH 48027-100)  or Fuel Pressure Relief (Without CH 48027-100) .
    2. NOTE: Ensure that the fuel tank is completely drained because of the severe angle that the tank will need to be tipped, in order to remove the tank.
  2. Drain the fuel tank. Refer to Fuel Tank Draining (Non E-85) .
  3. Remove the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement (Convertible) .
  4. Remove the fuel pump module access cover bolts.
  5. Remove the fuel pump module access cover.
    6. Fig 2: Identifying Fuel Tank Sensors Electrical Connectors
    GM1594359Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel sending unit electrical connector (3).
  7. Disconnect the fuel tank pressure sensor electrical connector (5).
  8. Disconnect the evaporative emission (EVAP) canister vent solenoid electrical connector (2).
    9. Fig 3: Identifying Fuel Feed & Canister Purge Line Quick Connect Fitting
    GM1765563Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel pump fuel feed line quick connect fitting (1) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Disconnect the EVAP canister purge line quick connect fitting (2) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Secure the fuel feed and EVAP purge lines up out of the way.
    12. Fig 4: Identifying EVAP Line Quick Connect Fitting
    GM1765565Courtesy of GENERAL MOTORS CORP.
  12. Remove the fuel fill pipe. Refer to Fuel Tank Filler Pipe Replacement .
  13. Disconnect the fuel tank fill pipe EVAP line quick connect fitting (1) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Remove the fuel tank fill EVAP line out through the access hole in order to prevent damage to the pipe when removing the tank.
  15. Remove the rear suspension crossmember. Refer to Rear Suspension Support Crossmember Replacement .
  16. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement .
  17. Position an adjustable jack under the fuel tank.
    18. Fig 5: Identifying Fuel Tank Strap & Support Bolts
    GM1594355Courtesy of GENERAL MOTORS CORP.
  18. Remove the fuel tank strap/support bolts (2).
  19. Remove the fuel tank support bolts (3).
  20. Remove the fuel tank supports (1).
    21. Fig 6: View Of Fuel Tank
    GM1594371Courtesy of GENERAL MOTORS CORP.
  21. Remove the adjustable jack from under the fuel tank and with the aid of an assistant, tilt the tank down towards the left side of the vehicle and carefully remove the tank.
  22. Place the fuel tank onto a suitable work surface.
  23. Cap or plug the fuel feed and EVAP lines in order to prevent fuel loss and/or system contamination.
    24. Fig 7: Identifying EVAP Line
    GM1594375Courtesy of GENERAL MOTORS CORP.
  24. If the fuel tank is being replaced, perform the following:
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