2004 Saturn Ion Red LineFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install the fuel filler pipe assembly into position on the vehicle.
  2. Connect the fuel filler hose to the fuel tank.
  3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel filler pipe assembly lower retaining bolt.

    Tighten:Β  Tighten the bolt to 10 N.m (89 lb in).

  5. Fig 1: Locating Fuel Filler Pipe Assembly Lower Retaining Bolt
    GM879143Courtesy of GENERAL MOTORS CORP.
  6. Tighten the fuel filler hose clamp (1) at the fuel tank.

    Tighten:Β  Tighten the clamp to 4.5 N.m (40 lb in).

  7. Fig 2: Fuel Filler Pipe Jumper Hose
    GM889977Courtesy of GENERAL MOTORS CORP.
  8. Connect the EVAP vent pipe (1) to the EVAP canister. Refer to Quick Connect Fitting(s) Service (Plastic Collar) (Press Release)Β .
  9. Fig 3: View Of EVAP Pipes
    GM889726Courtesy of GENERAL MOTORS CORP.
  10. Lower the vehicle.
  11. Install the fuel filler pipe assembly upper retaining bolt.

    Tighten:Β  Tighten the bolt to 10 N.m (89 lb in).

  12. Fig 4: Locating Fuel Filler Pipe Assembly Upper Retaining Bolt
    GM879144Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel filler pocket. Refer to Fuel Filler Pocket Replacement in Body Rear End.
  14. Refill the fuel tank.
  15. Install the fuel fill cap.
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:

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

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