GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 VUE - AWD 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 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 a hoist.

    3. 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.

  3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  4. Disconnect the negative battery cable.
  5. Raise the vehicle on a hoist.

    6. Object Number: 892074 Size: SH
  6. Remove the rubber exhaust hangers on order to allow the exhaust system to drop slightly.
  7. Remove the propeller shaft guard, if equipped.
  8. Remove the propeller shaft, if equipped. Refer to Propeller Shaft Replacement in Propeller Shaft.

    9. Object Number: 933942 Size: SH

    Notice: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

  9. Disconnect the EVAP canister vent and fresh air hoses:
    10. 9.1. Grasping both sides of the quick-connect fitting, twist the female connector 1/4 turn in each direction in order to loosen dirt within the quick-connect fitting.
    9.2. Blow any dirt out of the quick-connect fitting using compressed air.
    9.3. Squeeze the plastic retainer release tabs.
    9.4. Pull the connection apart.
    9.5. Inspect both ends of the quick-connect fitting for dirt and burrs.

    Object Number: 927728 Size: SH
  10. Remove the fuel filler pipe, EVAP vent hose, and fresh air hose from the fuel tank.

    11. 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.

  11. Disconnect the chassis fuel supply line from the fuel filter outlet.
  12. Disconnect the fuel tank ground strap fastener.
  13. Disconnect the fuel tank electrical connector.

    14. Object Number: 927748 Size: SH

    Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.

    Important: Do not disassemble the RDM. It is not necessary to touch the RDM for fuel tank removal.

  14. Support the fuel tank.
  15. Remove the fuel tank strap bolts and fuel tank straps.
  16. Lower the fuel tank from the underbody of the vehicle.

Disassembly Procedure

    Object Number: 933880 Size: SH
  1. Place the fuel tank in a suitable work area.
  2. Remove the primary fuel pump module from the fuel tank. Refer to Primary Fuel Tank Module Replacement .

    3. Object Number: 933876 Size: SH
  3. Remove the secondary fuel pump module from the fuel tank. Refer to Secondary Fuel Tank Module Replacement .
  4. Remove the fuel and EVAP lines from the fuel tank.
  5. Remove the electrical harness from the fuel tank.

Assembly Procedure

    Object Number: 933876 Size: SH

    Important: Always replace the fuel pump module-to-tank seal, H-ring, whenever the assembly is removed.

  1. Install the primary fuel pump module into the fuel tank. Refer to Primary Fuel Tank Module Replacement .

    2. Object Number: 933798 Size: SH
  2. Install new the new fuel filter onto the fuel tank.

    3. Tighten
    Tighten the fuel filter bracket bolt to 2 N·m (18 lb in).

  3. Install the fuel and EVAP lines onto the fuel tank:
    4. 3.1. Apply a few drops of clean engine oil to the male fuel pipe end.
    3.2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs/fingers to snap into place.
    3.3. Pull both sides of the quick-connect in order to make sure the connection is secure, once installed.

Installation Procedure

    Object Number: 927757 Size: SH
  1. Install the fuel tank heat shield and fuel tank assembly into the vehicle.

    2. Object Number: 927748 Size: SH
  2. Install the fuel tank straps and tighten the bolts.

    3. Tighten
    Tighten the fuel tank strap-to-body bolts to 25 N·m (18 lb ft).


    Object Number: 927728 Size: SH
  3. Install the fuel filler pipe, EVAP vent, and fresh air hoses to the fuel tank.
  4. Tighten the hose clamp on the filler pipe-to-fuel tank connecting hose.

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

  5. Install the fuel tank ground strap fastener, by the fuel filter.

    6. Tighten
    Tighten the ground strap-to-body bolt to 8 N·m (71 lb in).


    Object Number: 933942 Size: SH
  6. Connect the EVAP canister vent and fresh air hoses to the fuel tank hoses.
  7. If equipped, install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
  8. If equipped, install the propeller shaft guard.

    9. Object Number: 892074 Size: SH
  9. Install the rubber exhaust hangers.
  10. Lower the vehicle from the hoist.
  11. Fill the fuel tank with gasoline.
  12. Connect the negative battery cable.

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

  13. Prime the fuel system:
    14. 13.1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
    13.2. Repeat the previous step twice.
    13.3. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    13.4. If the engine does not start, repeat steps 13.1-13.3.