2004 Saturn Ion Red LineFACTORY OEM SERVICE PROCEDURE

Removal Procedure

CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.
  1. Remove the fuel fill cap.
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Remove the fuel filler pocket. Refer to Fuel Filler Pocket Replacement in Body Rear End.
  4. Remove the fuel filler pipe assembly upper retaining bolt.
    5. Fig 1: Locating Fuel Filler Pipe Assembly Upper Retaining Bolt
    GM879144Courtesy of GENERAL MOTORS CORP.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Disconnect the evaporative emission (EVAP) vent pipe (1) from the EVAP canister. Refer to Quick Connect Fitting(s) Service (Plastic Collar) (Press Release) .
    7. Fig 2: View Of EVAP Pipes
    GM889726Courtesy of GENERAL MOTORS CORP.
  7. Loosen the fuel filler hose clamp (1) at the fuel tank.
    8. Fig 3: Fuel Filler Pipe Jumper Hose
    GM889977Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel filler pipe assembly lower retaining bolt.
    9. Fig 4: Locating Fuel Filler Pipe Assembly Lower Retaining Bolt
    GM879143Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel filler hose from the fuel tank.
  10. Remove the fuel filler pipe assembly.
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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