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Home >> Saturn >> 2009 >> Aura Green Line >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 2.4L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure

Removal Procedure

NOTE: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination.
    Fig 1: Identifying Fuel Pump Module & EVAP Canister Wiring Harness Connectors
    GM1795275Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (with CH 48027-100)  or Fuel Pressure Relief (w/o CH 48027-100) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Disconnect the fuel tank fuel pump module wiring harness electrical connector (1) from body wiring harness electrical connector (2).
  5. If equipped, disconnect the fuel pressure sensor electrical connector.
  6. Remove the body wiring harness electrical connector clip (3) from the EVAP canister.
    7. Fig 2: Identifying ABS Wiring Harness Connector & Clip
    GM1795267Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the body wiring harness electrical connector (2) from the rear antilock brake system (ABS) wiring harness electrical connector (1).
  8. Remove the rear ABS wiring harness electrical connector (3) clip from the EVAP canister.
    9. Fig 3: Identifying Fuel Tank & Chassis Fuel Feed Pipes
    GM1789402Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
  10. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
  11. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.
    12. Fig 4: Identifying Fuel Fill Pipe & Clamp, EVAP Emission Pipe & Fuel Tank Vent Pipe
    GM1795261Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting (2) from the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
    13. Fig 5: Identifying Muffler Insulators
    GM1787817Courtesy of GENERAL MOTORS CORP.
  13. Place a jackstand under the muffler assembly.
  14. With the aid of an assistant, separate the muffler insulators (1) from the underbody hangers.
  15. Slowly lower the muffler assembly allowing it to rest on the jackstand. If this is not possible, remove the muffler assembly. Refer to Exhaust Muffler Replacement (LAT and LZ4) or Exhaust Muffler Replacement (LE5 With MH8) .
    16. Fig 6: View Of Fuel Tank Strap & Bolts
    GM1795255Courtesy of GENERAL MOTORS CORP.
  16. Have assistants support either side of the fuel tank.
  17. Place a suitable adjustable jack under the fuel tank.
  18. Remove fuel tank strap bolts and straps.
  19. Have the assistants rest the fuel tank on the adjustable jack.
  20. If applicable, in order to clear the muffler assembly, slowly lower the right side of the fuel tank.
  21. Once the tank is clear of the right frame rail, lower the fuel tank down and remove forward toward the right side of the vehicle.
  22. If replacing the fuel tank, proceed to the disassembly procedure, if not proceed to the Installation Procedure.
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