GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 L300/LW300 🢒 Engine 🢒 Engine Controls - 3.0L (L81) 🢒 Fuel Tank Replacement

Removal Procedure

    Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

  1. Ensure that the 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: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  2. Position the vehicle on the hoist.

    3. Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

  3. Disconnect the negative battery cable.

    4. Object Number: 894300 Size: SH

    Caution: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

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

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

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

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

    9. Object Number: 892352 Size: SH

    Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12  in) diameter to adequately catch the fluid.

  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 recirc line.

    12. Important: If there are 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 not located near the fuel filter.
  14. Remove the fuel tank strap bracket, the 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

    Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

  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 towards the rear.
    19.2. Remove the fuel tank from the vehicle.

Installation Procedure

    Object Number: 892353 Size: SH
  1. With the aid of an assistant, position the fuel tank with the heat shield and the straps under the vehicle.
  2. Attach the electrical connectors to the fuel pump and the tank pressure sensor.
  3. Reposition the fuel tank mounting straps and the 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).

    Notice: 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 the new retainers into the female portion of the quick-connect fittings 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 the vapor lines.
  6. Install the fuel tank grounding attachment nut located near the fuel filter.

    7. Tighten
    Tighten the fuel tank grounding attachment nut to 4.5 N·m (40 lb in).

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


    Object Number: 893228 Size: SH
  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 the 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 the underbody.

    12. Tighten
    Tighten the fuel fill pipe-to-body (lower) to 13 N·m (115 lb in).

  12. Install the heat shield

    13. Tighten
    Tighten the rear heat shield to 8 N·m (69 lb in).


    Object Number: 885839 Size: SH
  13. Install the fuel tank strap bracket, the fuel line stone chip guard.

    14. Tighten
    Tighten the fuel tank stone guard-to-body to 10 N·m (89 lb in).


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