2004 Saturn Ion Red LineFACTORY OEM SERVICE PROCEDURE

Fuel System Cleaning

IMPORTANT: If the fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
  2. Remove the fuel pump module assembly. Refer to Fuel Pump Module Replacement .
  3. Inspect the fuel pump module strainer. Replace the pump module assembly if the fuel strainer is contaminated.
    4. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water in accordance with all applicable local, state, and federal laws and regulations.
  4. Flush the fuel tank with hot water.
  5. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete.
  6. Allow the tank to dry completely before reassembly.
  7. Disconnect the fuel feed pipe at the engine fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    8. IMPORTANT: Only use oil-free compressed air to blow out the fuel pipes.
  8. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow.
  9. Connect the fuel feed pipe to the engine fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  10. Install the fuel pump module assembly. Refer to Fuel Pump Module Replacement .
  11. Install the fuel tank. Refer to Fuel Tank Replacement .
  12. Replace the fuel filter. Refer to Fuel Filter Replacement .
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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