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Home >> Saturn >> 2007 >> Relay 3.9 1 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Replacement (Short Wheel Base) >> Installation Procedure

Installation Procedure

    Fig 1: Identifying Fuel Tank Strap Bolts & EVAP Canister Nut
    GM1682268Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, remove the fuel tank from the work surface and place on the adjustable jack.
  2. With the aid of the assistant, support and install the fuel tank.
    3. NOTE: Refer to Fastener Notice .
  3. Position the fuel tank straps (1) and install the strap bolts (2).

    Tighten:  Tighten the bolts to 47 N.m (35 lb ft).

  4. Remove the adjustable jack.
    5. Fig 2: Identifying EVAP Canister Nut
    GM1682269Courtesy of GENERAL MOTORS CORP.
  5. Install the EVAP canister nut (1).

    Tighten:  Tighten the nut to 9 N.m (80 lb ft).

    6. Fig 3: Identifying Fuel Tank Wiring Harness & Connectors
    GM1682267Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel tank wiring harness (2) electrical connector to the body wiring harness pass-through.
  7. Install the fuel tank wiring harness to the electric brake harness clips (1).
    8. Fig 4: Identifying Fuel Tank Fill Hose & Clamp
    GM1682044Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel fill hose to the fuel tank (4).
  9. Tighten the fuel fill hose clamp (5) at the fuel tank.

    Tighten:  Tighten the clamp to 2.5 N.m (22 lb in).

  10. Connect the fuel fill pipe vapor recirculation pipe (2) quick connect fitting to the fuel tank vapor recirculation hose (3). Refer to Plastic Collar Quick Connect Fitting Service .
    11. Fig 5: Identifying Fuel Tank Feed Pipe Quick Connect Fitting
    GM1682041Courtesy of GENERAL MOTORS CORP.
  11. Connect the EVAP pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Connect the fuel feed pipe (1) quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  13. Lower the vehicle.
  14. Add fuel to the fuel tank.
  15. Install the fuel fill cap.
  16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  17. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect the fuel system for fuel leaks.
  18. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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