Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Saturn Ion Red LineFACTORY OEM SERVICE PROCEDURE
Removal Procedure
WARNING: This page is about a different car, the 2005 Saturn Ion 3, 2005 Saturn Ion 2, and 2005 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
Refer to Gasoline/Gasoline Vapors Caution
in Cautions and Notices.
- Remove the fuel pump module assembly. Refer to Fuel Pump Module Replacement .
- Release the fuel level sensor wiring harness from the molded-in tab (1) on the pump module bowl.
- Disconnect the fuel level sensor electrical connector from the pump module.
- Depress the retaining tab (2) on the sensor and begin to slide the level sensor away from the pump module.
- Carefully slide the level sensor the rest of the way off of the pump module.
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.