Saturday, June 18, 2011

How to remove Fuel Tank removal for 2000 - 2003 Saturn L300?

1 Remove the fuel filler cap from the gas tank to relieve any built-up pressure in the tank.

2 Look under the center console for the fuel pump relay. You will see a box with 12 fuses. The relay is clearly labeled with a "- 10 -". Switch off the relay fuse.

3 Start the engine and wait for it to stall. This will tell you when all the pressure has been relieved in the fuel system and the fuel within the pump lines is completely used up.

4 Remove the negative cable from the battery terminal with a socket wrench.

5 Siphon all remaining fuel from the fuel tank with a fuel siphon.

6 Raise the 2000 Saturn with a jack. Lower the vehicle onto jack stands.

7 Remove the rubber grommet around the top of the fill pipe. Use a socket wrench to remove the screw under the grommet.

8 Disconnect the fuel tank sensor and fuel pump unit. These two wires are located under the car, just above the fuel tank.

9 Disconnect the fill pipe with a socket wrench. Use a ratchet to release the clamps.

10 Remove the fill pipe. It should slide off once the clamps are removed.

11 Disconnect the filter/pressure regulator, which is located near the fuel tank, and slide it out of the way.

12 Support the fuel tank on a wood block using the floor jack to hold it in position directly under the tank. This will prevent the tank from falling and cracking.

13 Remove the retaining straps holding the tank in position with a socket wrench. Carefully lower the tank.

14 Hammer the lock ring on top of the fuel tank loose with a brass punch. Do this carefully to avoid damaging the piece, tapping the ring counterclockwise.

15 Pull the old assembly out of the tank and set the new one inside.

16 Reassemble the fuel tank and secure it back onto the 2000 Saturn.

17 Raise the Saturn above the jack stands. Remove the stands and lower the vehicle to the ground. Reconnect the negative cable to the battery. Switch on the fuel pump relay fuse. Close the hood.


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