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

Removal Procedure

NOTE: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.
    Fig 1: Identifying Fuel Tank Feed Pipe Quick Connect Fitting
    GM1682041Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  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 feed pipe (1) quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Disconnect the evaporative emission (EVAP) pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
    6. Fig 2: Identifying Fuel Tank Fill Hose & Clamp
    GM1682044Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel fill pipe vapor recirculation pipe (2) quick connect fitting from the fuel tank vapor recirculation hose (3). Refer to Plastic Collar Quick Connect Fitting Service .
  7. Loosen the fuel fill hose clamp (5) at the fuel tank.
  8. Remove the fuel fill hose from the fuel tank (4).
    9. Fig 3: Identifying Fuel Tank Wiring Harness & Connectors
    GM1682267Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel tank wiring harness (2) electrical connector from the body wiring harness pass-through.
  10. Remove the fuel tank wiring harness from the electric brake harness clips (1).
    11. Fig 4: Identifying EVAP Canister Nut
    GM1682269Courtesy of GENERAL MOTORS CORP.
  11. Center an adjustable jack under the fuel tank.
  12. Remove the EVAP canister nut (1).
    13. Fig 5: Identifying Fuel Tank Strap Bolts & EVAP Canister Nut
    GM1682268Courtesy of GENERAL MOTORS CORP.
  13. Remove the fuel tank strap bolts (2), and reposition the fuel tank straps (1).
  14. With the aid of an assistant, support and lower the fuel tank (3).
  15. Remove the fuel tank from the adjustable jack and place on a suitable work surface.
  16. If the fuel tank is not being replaced, proceed to the installation procedure.
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