Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



1991-97 Models

See Figures 1 through 8

To prevent excessive fuel spillage, whenever the tank is removed from the vehicle, it should be no more than 3 / 4 full. Removal of the fuel pump module assembly requires removal of the fuel tank.


CAUTION
The following procedure will produce a small fuel spill and fumes. Make sure there is proper ventilation and be sure to take the appropriate fire safety precautions.

  1. Disconnect the negative battery cable, then properly relieve the fuel system pressure. Refer to the procedure in this section.
  2.  
  3. Remove the fuel filler cap, then raise and support the vehicle safely using jackstands, with the rear of the vehicle approximately 28 in. (711mm) higher than the front (to keep any fuel in the tank forward and away from the fill hose).
  4.  
  5. Clean the area surrounding the filler neck to avoid fuel system contamination, then position a container with a minimum 12 in. (300mm) diameter opening under the filler neck to catch any escaping fuel. Loosen the filler neck clamp at the rear of the fuel tank, wrap a shop rag around the neck tube and carefully remove the tube from the tank.
  6.  
  7. For 1991-92 vehicles, inside the filler on the tank is a check ball to prevent fuel from flowing out of the filler in the event of vehicle roll-over. If the tank needs to be drained on these models, the check ball must be dislodged. Use the large round end of a 1 / 2 in. drive ratchet extension (which is at least 18 in. long) to push the check ball into the fuel tank. For 1993-97 vehicles, the fuel check ball was relocated to the filler pipe, so that the pipe may simply be removed to allow siphoning. These filler pipes can be installed in 1991-92 vehicles, but the check ball must first be removed from the tank.
  8.  

Once the check ball has been knocked into the fuel tank on 1991-92 models, the tank must be removed from the vehicle. The pump module must then be removed from the tank in order to reinstall the check ball.

  1. If the check ball was dislodged (1991-92 models) or the fuel neck removed (1993-97 models) for siphoning, use a clean length of hose and/or an appropriate hand pump to siphon or pump the fuel from the tank and into an approved gasoline container.
  2.  
  3. Remove the filler neck bracket fastener at the left side of the rear frame rail, then loosen the fuel vent hose retaining clamp at the tank.
  4.  

It is easier to remove hoses from the tank than to pull them from the steel vent and fill tubes.

  1. Disconnect the fuel pressure and return line quick-connects by pinching the 2 plastic tangs together, then grasp both ends of one fuel line connection and twist 1 / 4 turn in each direction while pulling them apart. Disconnect the fuel vent hose by holding the line and by pushing on the rubber connector with a small open end wrench.
  2.  

Do not allow the fuel tank retaining straps to become bent during tank removal, otherwise strap damage and/or breakage may occur. Always utilize an assistant when removing the fuel tank to prevent damage.

  1. With the aid of an assistant, remove the 2 support strap fasteners at the rear of the tank, then lower the tank and support panel approximately 8 in. (203mm). Reach upward and unplug the electrical connector from the top of the tank, then remove the tank and support panel from the vehicle.
  2.  
  3. If the check ball was removed or fuel pump module replacement/service is necessary:
    1. Clean the area surrounding the fuel pump module and spray the cam lockring tangs with a suitable penetrating oil to loosen the fitting.
    2.  
    3. Using SA9156E, or an equivalent fuel module lockring removal tool, and a 1 / 2 in. breaker bar of approximately 18 in. (457mm) length, remove the pump unit locking ring from the tank. Attempting to use a 12 in. or shorter breaker bar may cause lockring damage.
    4.  
    5. Lift and tilt the unit out at a 45 degree angle, being careful not to bend the sending unit float arm. Remove and discard the unit-to-tank O-ring.
    6.  

  4.  
  5. The sending unit is the only portion of the module that may be serviced. The filter may be cleaned with mineral spirits, but must be replaced as an assembly with the module if damaged. If necessary, remove the sending unit from the module as follows:
    1. Unplug the 2 electrical connections using needlenose pliers or by pressing down the locking tab and pulling the connectors from the terminal.
    2.  
    3. Using a small suitable tool, push in on the sender assembly attaching tang, then lift upward and remove the sender.
    4.  
    5. Late 1992 and all 1993-94 vehicles use a brass float instead of plastic. Brass floats may be serviced. Use a 1 / 4 in. flat-tipped screwdriver to carefully pry the float from the wire loop. Do not bend the float arm or deform the wire loop.
    6.  

  6.  

To install:
  1. If removed, pinch a brass float onto the float arm wire loop and/or install the sending unit to the pump module by positioning the tang in the locator slot and snapping the unit into place. Attach the 2 sending unit electrical connectors to their terminals.
  2.  
  3. If removed for service or access to the check ball, install the fuel pump assembly:
    1. Before installing the pump module, remove the filler check ball and examine it for cracks or damage. Reach into the tank through the pump unit hole and carefully push the check ball into the filler tube opening from the inside. If necessary, carefully spread the plastic ball supports to ease installation.
    2.  
    3. Install a new O-ring to the opening in the top of the fuel tank, then carefully insert the pump module into the tank at a 45 degree angle to prevent sending unit and float damage. The filter and flow arm must be directed toward the front of the tank.
    4.  
    5. Align the pump locator tabs with the fuel tank slots, then install the cam lockring using the ring service tool.
    6.  

  4.  
  5. With the aid of an assistant, position the tank and support panel so the wires can be connected to the module, install the module electrical connector, then secure the tank in place using the retaining straps. Tighten the strap bolts to 35 ft. lbs. (47 Nm).
  6.  
  7. Loosely install the filler tube, vent lines and clamps. Align the filler neck and tank so the fender will not be deflected or pushed outward by the hose. When everything is properly positioned, install the fill neck tube and bracket fastener. Vent lines should be installed into the rubber boot until the tube white marks align with the side of the boot.
  8.  
  9. Tighten the clamps to 18 inch lbs. (2 Nm) and tighten the fill neck bracket fastener to 53 inch lbs. (6 Nm). If the clamps must be replaced, original equipment or equivalent parts must be used, because the original parts are designed to prevent hose damage.
  10.  
  11. Lubricate the male ends of the fuel supply and return quick-connect fittings with a few drops of clean engine oil. Push the connectors together until the retaining tabs snap into place, then pull on opposite ends of each connection to verify that the connection is secure.
  12.  
  13. Remove the jackstands and carefully lower the vehicle, then install the fuel filler cap and connect the negative battery cable.
  14.  
  15. Prime the fuel system and check for leaks:
    1. Turn the ignition ON for 5 seconds, then OFF for 10 seconds.
    2.  
    3. Repeat the ON/OFF cycle 2 more times.
    4.  
    5. Crank the engine until it starts.
    6.  
    7. If the engine does not readily start, repeat Steps a-e.
    8.  
    9. Run the engine and check for leaks.
    10.  

  16.  



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Fig. Fig. 1: For 1991-92 vehicles with the check ball installed in the fuel tank, use an 18 in. or longer ratchet extension to dislodge the fuel filler check ball, knocking it into the tank. The tank will need to be removed, in order to retrieve the ball for installation



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Fig. Fig. 2: View of the fuel filler neck-1992 SC model shown



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Fig. Fig. 3: Exploded view of a typical fuel tank/pump module and hose assembly



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Fig. Fig. 4: Position the lockring removal tool so as not to damage the fuel and vapor lines



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Fig. Fig. 5: Tilt and remove the pump module assembly, being careful not to damage the filter sending unit and float arm



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Fig. Fig. 6: Unplug the electrical connectors by pressing down the locking tab, then pulling the connectors from their terminals



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Fig. Fig. 7: Use a 1/4 in. flat tipped tool to push in the attachment tang and lift upward on the sender



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Fig. Fig. 8: Before installing the fuel pump module, push the fuel check ball into position

1998 Models

See Figures 3, 4, 5, 6, 9, 10, 11, 12 and 13

To prevent excessive fuel spillage, whenever the tank is removed from the vehicle it should be no more than 1 / 2 full. Removal of the fuel pump module assembly requires the removal of the fuel tank.


CAUTION
The following procedure will produce a small fuel spill and fumes. Make sure there is proper ventilation and be sure to take the appropriate fire safety precautions.

  1. Disconnect the negative battery cable, then properly relieve the fuel system pressure. Refer to the procedure in this section.
  2.  
  3. Remove the fuel filler cap and rubber closeout grommet (inside fuel filler door). Remove the mounting fastener (using a T-30 Torx® bit) at the upper end of the fuel tank filler pipe.
  4.  
  5. Raise and support the vehicle safely using jackstands, with the rear of the vehicle at a comfortable working height.
  6.  
  7. Remove the wheel house inner fender liner.
  8.  
  9. Disengage the wiring harness connector from the EVAP canister vent solenoid.
  10.  
  11. Remove the fuel tank filler pipe lower bracket mounting fastener located at the underbody left side rail.
  12.  
  13. Disconnect the EVAP canister vent tube at the 5 / 8 in. quick-connect fitting.
  14.  
  15. Loosen the fuel tank filler pipe hose clamp located closest to the tank.
  16.  
  17. Disconnect the filler pipe hose from the fuel tank, making sure that it is as straight and level as possible so as to prevent it from falling into the fuel tank. Remove the filler pipe from the vehicle. Be careful when disconnecting the filler hose as a residual amount of fuel may be left sitting in the filler pipe due to the inlet check valve on the fuel tank.
  18.  
  19. If there is more than 3 gallons of fuel in the tank, insert a siphon hose into the filler neck and drain into an approved gasoline container.
  20.  


CAUTION
Whenever fuel line fittings are loosened or disconnected, always wrap a shop towel around the fitting and have a suitable container available to catch any fuel spill.

  1. Disengage the fuel feed line from the outlet tube of the filter/pressure regulator. If necessary, refer to General Information & Maintenance for service information on the fuel filter/pressure regulator.
  2.  
  3. Disengage the fuel vapor/canister purge line at the fitting adjacent to the filter/pressure regulator.
  4.  
  5. Remove the fuel filter/pressure regulator bracket from under the brake lines.
  6.  
  7. With the aid of an assistant, remove the 2 fuel tank retaining strap mounting bolts. Lower the tank just enough to disengage the 2 electrical connectors from the fuel pump and pressure sensor.
  8.  
  9. Carefully remove the fuel tank from the vehicle.
  10.  
  11. If fuel pump module replacement/service is necessary:
    1. Clean the area surrounding the fuel pump module and spray the cam lockring tangs with a suitable penetrating oil to loosen the fitting.
    2.  
    3. Using SA9156E, or an equivalent fuel module lockring removal tool, and a 1 / 2 in. breaker bar of approximately 18 in. (457mm) length, remove the pump unit locking ring from the tank. Attempting to use a 12 in. or shorter breaker bar may cause lockring damage.
    4.  
    5. Lift and tilt the unit out at a 45 degree angle, being careful not to bend the sending unit float arm. Remove and discard the unit to tank O-ring.
    6.  

  12.  
  13. The sending unit is the only portion of the module that may be serviced. The filter may be cleaned with mineral spirits, but must be replaced as an assembly with the module if damaged. If necessary, remove the sending unit from the module as follows:
    1. Unplug the electrical connector from the fuel level sending unit by disengaging the locking tab and pulling the connector from the terminal.
    2.  
    3. Holding the fuel pump module in both hands, and applying firm upward pressure at the bottom of the fuel sending unit using both thumbs, push the sender toward the top of the module to disengage the bottom attachment clip.
    4.  

  14.  

To install:
  1. Install the sending unit to the pump module by positioning the attachment clip in the locator slot and snapping the component into place. Verify that the sending unit float arm has the correct relationship to the fuel pump module by holding the component up on a flat, horizontal surface and measuring. Using a 5 / 32 in. diameter drill bit, it must easily pass between the float and the horizontal surface with no more than 1 / 16 in. clearance. If bending the float arm is required to meet the clearance specification, it must be performed at the 90° bend near the level sender while supporting the short section of the arm.
  2.  
  3. Connect the wiring harness from the fuel pump module to the sending unit. Press firmly to engage.
  4.  
  5. Install the fuel pump assembly as follows:
    1. Before installing the pump module, inspect the fuel tank and clean the seal groove of any debris or foreign matter.
    2.  

  6.  

The correct fuel pump module O-ring seal is green in color. It is incorrect to use the older black seal.

  1. Connect the fuel pump vapor line to the tank vent pipe.
  2.  
  3. Connect the feed and return lines to the fuel filter/pressure regulator.
  4.  
  5. Place the feed, return and EVAP canister purge lines into the fuel tank retaining clip and snap closed.
  6.  
  7. Install the loose retainer clip around the fuel feed, return and purge lines and snap shut.
  8.  
  9. With the aid of an assistant, position the fuel tank so the wires can be connected to the pump module and pressure sensor.
  10.  
  11. Properly install the fuel tank under the vehicle by making certain that the small white locator button on the left side of the tank is positioned tightly against the left side rail.
  12.  
  13. Install the retaining straps and shield. Tighten the strap bolts to 35 ft. lbs. (47 Nm).
  14.  
  15. Place the fuel filter/pressure regulator in position and install the mounting screws in the bracket. Tighten the mounting screws to 71 inch lbs. (8 Nm).
  16.  
  17. Install a new retainer into the female portion of the 90° quick-connect fitting of the underbody fuel line.
  18.  
  19. Lubricate the outlet end of the filter/pressure regulator with clean engine oil and connect to the underbody fuel feed line.
  20.  
  21. Be sure that the fuel filler check valve is in correct position at the end of the filler pipe. Using plain water, lightly wipe the outside of the fuel tank inlet connector.
  22.  
  23. Position the fuel tank filler pipe into the wheel opening with the top of the pipe protruding out of the fender/filler door opening.
  24.  
  25. Insert the filler pipe into the fuel tank opening and loosely install the lower bracket attachment screw. Be sure that the EVAP vent solenoid pipe is installed in the correct position on the filler pipe bracket.
  26.  
  27. Lower the vehicle and install the fuel tank filler pipe upper bracket mounting fastener. Tighten the mounting fastener to 31-35 inch lbs. (3.5-4.5 Nm).
  28.  
  29. Install the rubber closeout grommet to the filler pipe and install the fuel cap.
  30.  
  31. Raise the vehicle to a comfortable working height.
  32.  
  33. The fuel pipe connecting hose should be installed to within 1 / 4 in. (6mm) of the stops on the fuel tank inlet connector and the hose clamp should be positioned within 3 / 16 in. (4mm) of the end of the connecting hose. Tighten the hose clamp to 35 inch lbs. (4 Nm).
  34.  
  35. Connect the EVAP canister vent pipe to the canister vent hose.
  36.  
  37. Tighten the lower mounting screw on the filler pipe to the underbody. Tighten the mounting screw to 71 inch lbs. (8 Nm).
  38.  
  39. Engage the wiring harness connector to the EVAP vent solenoid.
  40.  
  41. Install the wheel house inner fender liner.
  42.  
  43. Remove the jackstands and carefully lower the vehicle, then install the fuel filler cap and connect the negative battery cable.
  44.  
  45. Prime the fuel system and check for leaks:
    1. Turn the ignition ON for 5 seconds, then OFF for 10 seconds.
    2.  
    3. Repeat the ON/OFF cycle 2 more times.
    4.  
    5. Crank the engine until it starts.
    6.  
    7. If the engine does not readily start, repeat Steps a-c.
    8.  

  46.  
  47. Run the engine and check for leaks.
  48.  



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Fig. Fig. 9: Remove the rubber closeout grommet and mounting fastener at the upper end of the filler pipe



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Fig. Fig. 10: Disengage the EVAP canister vent pipe at the 5/8 in. quick-connect fitting



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Fig. Fig. 11: With the aid of an assistant, lower the fuel tank enough to disengage the pump and pressure sensor wiring harnesses



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Fig. Fig. 12: Apply firm upward pressure at the bottom of the fuel sending unit with both thumbs to disengage the attachment clip



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Fig. Fig. 13: Use a 5/32 in. diameter drill bit to measure float arm clearance

 
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