2004 Saturn Ion Red LineFACTORY OEM SERVICE PROCEDURE

Removal Procedure

CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Disconnect the fuel feed and return lines from the fuel filter.
  5. Cap or plug the fuel tank feed and return pipes to prevent fuel loss and/or contamination.
  6. Disconnect the following evaporative emission (EVAP) pipe fittings, for access to disconnect the fuel filler hose from the tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) (Press Release) .
    • The EVAP purge pipe (2) from the EVAP canister
    • The fuel tank EVAP vapor pipe (3) from the EVAP canister
  7. Cap or plug the EVAP purge (2) and vapor (3) pipes to prevent contamination.
    8. Fig 1: View Of EVAP Pipes
    GM889726Courtesy of GENERAL MOTORS CORP.
  8. Loosen the fuel filler hose clamp (1) at the fuel tank.
    9. Fig 2: Fuel Filler Pipe Jumper Hose
    GM889977Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel filler hose from the fuel tank.
  10. Disconnect the fuel pump module harness electrical connector from the vehicle underbody connector.
    11. Fig 3: Locating Fuel Pump Module Harness Electrical Connector
    GM889730Courtesy of GENERAL MOTORS CORP.
  11. Release the exhaust extension pipe insulators from the underbody hangers.
  12. Release the muffler insulator from the underbody hanger and slowly lower the exhaust to rest on the rear axle beam.
    13. Fig 4: View Of Muffler Insulator
    GM1382235Courtesy of GENERAL MOTORS CORP.
  13. Have an assistant support the fuel tank during fuel tank strap removal, and during tank removal.
  14. Remove the LH fuel tank strap bolts and the strap.
  15. Remove the RH tank strap bolts and the strap.
    16. Fig 5: View Of Fuel Tank Strap Bolts
    GM890002Courtesy of GENERAL MOTORS CORP.
  16. In order to clear the exhaust extension pipe, slowly lower the RH side of the fuel tank. Use care in feeding the fuel feed and return pipes, the EVAP vapor pipe, and the fuel pump module electrical harness to clear the axle.
  17. Once the tank is clear of the RH frame rail, remove the fuel tank down and toward the RH side of the vehicle.
  18. If the fuel tank only is to be replaced, remove the fuel pump module assembly from the fuel tank. Refer to Fuel Pump Module 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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