2005 Saturn Ion 1 AutomaticFACTORY 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. Fig 1: View Of EVAP Pipes
    GM889726Courtesy of GENERAL MOTORS CORP.
  7. Cap or plug the EVAP purge (2) and vapor (3) pipes to prevent contamination.
  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.
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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.