GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Fuel Tank Replacement

Removal Procedure

    Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

  1. Ensure that fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining .

    2. Caution: Refer to Vehicle Lifting Caution in the Preface section.

  2. Position the vehicle on the hoist.
  3. Disconnect the negative battery cable.

    4. Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.

  4. Relieve the fuel system pressure. Refer to Fuel System Diagnosis .
  5. Raise the vehicle to a comfortable working position.

    6. Object Number: 891510 Size: SH
  6. Remove the exhaust system intermediate pipe with the muffler.

    7. Object Number: 892450 Size: SH
  7. Remove the rear heat shield retaining bolts.

    8. Object Number: 893228 Size: SH
  8. Remove the fuel filler pipe lower bracket attachment screw.

    9. Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.


    Object Number: 892352 Size: SH
  9. Disconnect the EVAP canister vent hose.
  10. Loosen the fuel filler pipe hose clamp closest to the fuel tank.
  11. Disconnect the quick connect at the recirculation line.

    12. Important: If there is more than 11.4 liters (3 gallons) of fuel in the tank, insert a suitable siphon hose into the tank filler neck and remove the remaining fuel into a certified fuel handling cart.

  12. Disengage the filler pipe hose from the fuel tank.

    13. Object Number: 885839 Size: SH
  13. Remove the tank grounding strap attachment nut located near the fuel filter.
  14. Remove the fuel tank strap bracket and fuel line stone chip guard, protecting the fuel line connections between the fuel tank and the chassis fuel bundle.

    15. Object Number: 892344 Size: SH
  15. Disconnect the fuel feed line after the fuel filter.
  16. Disconnect the fuel return and the EVAP canister purge lines between the tank and the chassis fuel bundle.
  17. Disconnect the fuel tank electrical connections.
  18. Loosen the front tank strap bolts, but do not remove.
  19. With the aid of an assistant, remove the 2 rear tank retaining strap bolts.
    20. 19.1. Lower the rear half of the tank and slide the fuel tank down and out rearward.
    19.2. Remove the fuel tank from the vehicle.

Installation Procedure

    Object Number: 892354 Size: SH
  1. With the aid of an assistant, position the fuel tank with the heat shield and straps under the vehicle.
  2. Attach the electrical connectors to the fuel pump and the tank pressure sensor.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Reposition the fuel tank mounting straps and shield around the tank and install the strap mounting bolts to the underbody.

    4. Tighten
    Tighten the fuel tank mounting strap to 20 N·m (15 lb ft).

    Important: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

  4. Install new retainers into the female portion of the quick-connect fitting on the underbody fuel and EVAP canister purge lines.

    5. Important: Lubricate the male ends of the filter with clean engine oil to ease installation.

  5. Connect the fuel feed, return, and vapor lines.
  6. Install the fuel tank grounding strap attachment nut located near the fuel filler neck.

    7. Tighten
    Tighten the fuel tank grounding strap attachment to 4.5 N·m (35 lb in).


    Object Number: 893228 Size: SH

    Important: Ensure that the EVAP vent solenoid pipe is installed in position on the filler pipe bracket.

  7. Loosely install the filler pipe lower bracket attachment screw but do not tighten.

    8. Object Number: 893316 Size: SH
  8. Install the fill neck to the fuel tank.

    9. Important: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6 mm (1/4 in) of the end of the connector hose.

  9. Tighten the hose clamp on the filler pipe to fuel tank connecting hose.

    10. Tighten
    Tighten the fuel fill neck-to-fuel tank clamp to 5 N·m (44 lb in).


    Object Number: 892767 Size: SH
  10. Connect the EVAP canister vent pipe at the quick connect to canister vent hose.
  11. Tighten the lower attachment screw on the filler pipe to underbody.

    12. Tighten
    Tighten the fuel fill pipe-to-body (lower) to 13 N·m (9.5 lb ft).

  12. Install the heat shield.

    13. Tighten
    Tighten the rear heat shield to 8 N·m (71 lb in).


    Object Number: 885839 Size: SH
  13. Install the fuel line stone chip guard.

    14. Tighten
    Tighten the fuel line stone chip guard to 12 N·m (106 lb in).


    Object Number: 891510 Size: SH
  14. Install the intermediate pipe with the muffler.
  15. Add fuel and connect the negative battery cable.

    16. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).

  16. Prime the fuel system.
    17. • Using the ignition, cycle the switch ON for 5 seconds and then OFF for 10 seconds. Repeat this twice.
    • Examine the fuel lines for leaks.
    • Crank the engine until it starts, allowing a maximum of 20 seconds of cranking time.