Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Fuel Filter

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On 1991-97 models, the fuel filter is attached to the vehicle frame in the lower left portion of the engine compartment. On 1998 models, the fuel filter and fuel pressure regulator are one integral component of the new returnless fuel injection system, and is located underneath the vehicle at the forward edge of the left side of the fuel tank. The filter should be serviced according to the Maintenance Intervals Chart at the end of this section.

REMOVAL & INSTALLATION



1991-97 Models

See Figures 1 through 8

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the fresh air intake hose from the camshaft or rocker cover and remove the air inlet tube.
  4.  
  5. Properly relieve the fuel system pressure as follows:
    1. Remove the air cleaner or air intake duct, as applicable.
    2.  
    3. Wrap a shop rag around the fuel test port fitting at the lower rear of the engine, remove the cap and connect pressure gauge tool SA9127E or equivalent.
    4.  
    5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. After the system pressure is bled, remove the gauge from the pressure test port and recap it.
    6.  

  6.  
  7. Clean the female end of the quick connect fitting by spraying it with penetrating oil, then detach the large underhood fuel line connection located near the intake manifold support brace on the left side of the vehicle using the tool supplied with the replacement filter, SA9157E or equivalent.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Disengage the quick connect fitting at the fuel filter inlet (rear of the filter) by pinching the 2 plastic tangs together and pulling on the supply line.
  12.  
  13. Loosen the fuel filter band clamp nut, but do not completely remove.
  14.  
  15. Carefully push or pull the filter out of the assembly and discard the filter in an appropriate container.
  16.  

To install:
  1. If the band clamp was removed, clip the fuel return and vapor lines in place and install 2 new band clamp nuts. Make sure all lines are in place and will not interfere with or be damaged by filter installation, then tighten the bracket nuts to 27 inch lbs. (3 Nm).
  2.  
  3. Clean the female end of the filter inlet quick connect fitting by holding the line facing downward and spraying penetrating oil up into the fitting. Be careful not to bend or kink the line.
  4.  
  5. If not already installed, insert a new snap lock retainer into the female end of the filter inlet quick connect fitting.
  6.  
  7. Route the filter' nylon outlet line through the band clamp and insert the filter far enough into the band clamp to connect the outlet line to the engine's fuel line attachment. Lubricate the male end of the connector with clean engine oil, snap the connector together and pull on the line to verify proper fitting.
  8.  
  9. Position the filter in the band clamp assembly with the filter' forward edge located 1 / 4 inch (6.35mm) from the front of the band clamp.
  10.  
  11. Lubricate the male end of the fuel supply line with clean engine oil. Snap the line into the fuel filter and pull back to verify that the fitting is secure. Tighten the band clamp nut to 89 inch lbs. (10 Nm).
  12.  
  13. Lower the vehicle and install the air cleaner or intake duct, as applicable. Connect the air inlet tube and fresh air hose.
  14.  
  15. Connect the negative battery cable, then prime the fuel system as follows:
    1. Turn the ignition ON for 5 seconds and 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 it does not start, repeat Steps a-c.
    8.  
    9. Run the engine and check for leaks.

      Click image to see an enlarged view

      Fig. Fig. 1: Exploded view of the fuel filter assembly



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      Fig. Fig. 2: Unscrew the protective cap from the fuel pressure relief valve



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      Fig. Fig. 3: Use a special fuel line quick-disconnect tool ...



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      Fig. Fig. 4: ... to disengage the filter from the fuel line



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      Fig. Fig. 5: Be sure to place a rag or paper towel below the fitting to absorb any fuel spillage



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      Fig. Fig. 6: Location of the fuel filter assembly



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      Fig. Fig. 7: Remove the fuel filter assembly from beneath the vehicle



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      Fig. Fig. 8: Position the engine side's edge of the fuel filter 1/4 in. (6mm) from the band clamp

    10.  

  16.  

1998 Models

See Figures 9 and 10

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Properly relieve the fuel system pressure as follows:
    1. Remove the air cleaner or air intake duct, as applicable.
    2.  
    3. Wrap a shop rag around the fuel test port fitting on the fuel supply line at the fuel rail. Remove the protective cap and connect pressure gauge tool SA9127E or equivalent.
    4.  
    5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. After the system pressure is bled, remove the gauge from the pressure test port and recap it.
    6.  

  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Loosen the fuel filter/pressure regulator bracket retaining screws.
  8.  


WARNING
Exercise extreme care when opening the retaining clip. The fuel lines must be retained in this clip; if damaged, the fuel tank assembly must be replaced, since the fitting is not serviced separately.

  1. Disengage the quick connect fitting on the left side of the fuel tank by pinching the 2 plastic tangs together and pulling on the supply line.
  2.  
  3. Disengage the EVAP purge line at the 90° quick connect fitting.
  4.  
  5. Slide the outlet of the fuel filter/regulator out of the support on the fuel tank bracket and disengage the fuel feed line at the 90° quick connect fitting.
  6.  
  7. Pivot the fuel filter/regulator down while moving the leg of the mounting bracket out from under the parking brake lines.
  8.  

It is not necessary to separate the fuel filter/regulator from the mounting bracket, since both items are serviced as an assembly.

  1. Disengage the fuel feed and return line quick connect fittings on the fuel filter/regulator. Discard the filter in an appropriate container.
  2.  

To install:
  1. Install new fuel line retainers (3) into the female portion of the quick connect fuel line fittings.
  2.  
  3. To ease installation, lubricate the male ends of the fuel filter/regulator with clean engine oil.
  4.  
  5. Install the fuel feed and return lines onto the fuel filter/regulator and snap them closed. Pull back to verify that the fittings are secure.
  6.  
  7. Install the fuel feed, return, and EVAP purge lines into the fuel tank's retaining clip.
  8.  
  9. Slide the leg of the fuel filter/regulator mounting bracket under the parking brake lines and pivot upward.
  10.  


WARNING
Be sure to route the chassis fuel feed and purge lines above the parking brake cable. The parking brake cable must be firmly secured to the underbody to support the fuel and purge lines.

  1. Install the 90° fuel feed line quick connect fitting onto the fuel filter/regulator outlet and snap it closed. Pull back to verify that the fitting is secure.
  2.  
  3. Install the 90° EVAP purge line quick connect fitting to the purge line and snap it closed. Pull back to verify that the fitting is secure.
  4.  
  5. Install the fuel feed outlet pipe of the fuel filter/regulator into the retaining clip on the fuel tank bracket.
  6.  
  7. Install the fuel filter/regulator bracket mounting screws. Tighten the bracket mounting screws to 71 inch lbs. (8 Nm).
  8.  
  9. Lower the vehicle and install the air cleaner or intake duct, as applicable. Connect the air inlet tube and fresh air hose.
  10.  
  11. Connect the negative battery cable, then prime the fuel system as follows:
    1. Turn the ignition ON for 5 seconds and 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 it does not start, repeat Steps a-c.
    8.  
    9. Run the engine and check for leaks.
    10.  

  12.  



Click image to see an enlarged view

Fig. Fig. 9: Fuel filter/pressure regulator location on the vehicle's underbody, at the forward edge of the left side of the fuel tank



Click image to see an enlarged view

Fig. Fig. 10: Removal of the fuel filter/pressure regulator bracket mounting fasteners

 
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