Tip & How-To about 2002 Saturn L-Series

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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Related Questions:

2 Answers

My vehical is leaking fuel from the gas tank


Most likely cause of this is the steel lines on the top of the tank being corroded, BUT,

-If it leaks only when you fill up, it could be the fill hoses.

-If it leaks as soon as you fire the vehicle up, it will be the fuel pump assembly being rusted (consists of a fuel pump, fuel gauge sensor, lines and wiring, and is located in, and at the top of the fuel tank)

-If it only starts to leak after you have been driving for a bit, over bumps etc, then most likely it is the tank itself

Hope this helps

Aug 14, 2011 | 1996 Ford Explorer

1 Answer

how do i depressurize the gas tank? on a 1995 nissan altima


HI,
If you mean the fuel line,start the engine, then remove the fuel pump relay , when not enough fuel pressure to run the engine, it will die and line will be depressurized. The tank itself only has minimal pressure which is vented. Removing the filler (gas) cap will relieve any excess pressure in the tank...Mike

Jul 30, 2011 | 1995 Nissan Altima

1 Answer

do i have to remove the tank to change the fuel pump


  • 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.
  • May 24, 2011 | 2006 Saturn L300

    1 Answer

    How do you remove the fuel pump from the bottom of the gas tank


    Hi there

    An in-tank fuel pump needs a full day of patience and tools (including a friend with a fire extinguisher to help).

    Start by relieving the fuel pressure, start the car and remove the fuel pump relay/fuse. The engine will die after a few moments. Undo the fuel filler screws, then on the inner trunk, remove carpets and side carpet, remove filler neck and screws.

    Hoist car securely, undo the tank straps, fuel lines (catch fuel that spills out, nip the fuel lines with wrench.

    Undo exhaust rear section and mounts. Undo fuel tank bolts, and lower it away from the car (with a friend as it will be heavy).

    Tank on the floor, open up the center aperture. Pull out the pump, refit new one and replace all parts.

    Hope this helps and vote if so :)

    Jul 08, 2010 | 2001 Nissan Xterra

    3 Answers

    how do you replace a fuel pump on 1994 jeep grand cherokee


    Disconnect the battery, Jack the rear up on stable jack stands. use a smaller jack with a piece of wood to stable the load under the tank. You will see 2 band straps under the tank, remove the bolts, only 1 side have bolts, the other side swings down. The hose from the gas cap will have to be disconnected, which can be !!!!! when in-stalling. you can then drop the gas tank down easily with the jack just a bit, enough to reach around to unplug the fuel pump plug, and the gas lines. Once it's removed, the pump has a big screw on ring, take it off and the fuel pump can be pulled out.

    Apr 26, 2010 | 1994 Jeep Grand Cherokee

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