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Home >> Saturn >> 2006 >> Relay 3.9 1, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Controls - 3.5L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (Short Wheel Base) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
NOTE: Refer to NYLON FUEL LINES NOTICE in Cautions and Notices.
IMPORTANT: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace the pipes.
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    4. Fig 1: Identifying Fuel Tank And Related Components
    GM1544794Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the fuel supply pipe (5) quick-connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Disconnect the evaporative emission (EVAP) purge pipe (6) quick-connect fitting at the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
    6. Fig 2: View Of Fuel Tank Filler Pipe At Fuel Tank
    GM49720Courtesy of GENERAL MOTORS CORP.
  6. Loosen the fuel tank filler pipe hose clamp.
  7. Disconnect the fuel tank filler from the fuel tank.
    8. Fig 3: Locating Vapor Recirculation Pipe At Filler Tube
    GM49730Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the vapor recirculation pipe from the filler tube.
  9. Remove the fuel tank shield.
    10. Fig 4: Locating Fuel Tank Strap Attaching Bolts
    GM49727Courtesy of GENERAL MOTORS CORP.
  10. With the aid of an assistant, support the fuel tank.
  11. Remove the fuel tank strap attaching bolts.
  12. Disconnect the fuel sender and the fuel tank pressure (FTP) sensor electrical connectors at the body pass through.
    13. Fig 5: View Of Fuel Tank
    GM49733Courtesy of GENERAL MOTORS CORP.
  13. Remove the fuel tank from the vehicle.
  14. Place the fuel tank in a suitable work area.
  15. If the fuel tank is not being replaced, go to the installation procedure.
  16. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement (Long Wheel Base)  or Evaporative Emission Canister Replacement (Short Wheel Base) .
    17. Fig 6: Identifying Fuel Tank And Related Components
    GM1544794Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the fuel feed quick-connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .
  18. Remove the fuel feed pipe (5).
  19. Remove the EVAP canister vent solenoid (2).
  20. Remove the EVAP pipe assembly.
  21. Remove the fuel sender assembly (3). Refer to Fuel Sender Assembly Replacement (Short Wheel Base)  or Fuel Sender Assembly Replacement (Long Wheel Base) .
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