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HOMESERVICE MANUALSSATURN2005ION 3 4D SEDAN, STANDARDREPAIR AND DIAGNOSISENGINE PERFORMANCESYSTEMENGINE CONTROLS - INTRODUCTIONREPAIR INSTRUCTIONSFUEL HOSE/PIPES REPLACEMENT - CHASSISREMOVAL PROCEDURE
2005 Saturn Ion 3 4D Sedan, Standard

Removal Procedure

2005 Saturn Ion 3 4D Sedan, StandardSECTION Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the pipe retaining clip (1) from the fuel feed pipe.
    3. Fig 1: Identifying Pipe Retaining Clip
    GM879147Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the fuel feed pipe from the engine fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  4. Cap or plug the fuel pipe and the engine fuel rail to prevent contamination.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Remove the evaporative emission (EVAP) canister for pipe removal access. Refer to Evaporative Emission (EVAP) Canister Replacement 
  7. Disconnect the fuel filter from the engine feed fuel pipe. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    8. Fig 2: Removing Fuel Filter From Engine Feed Fuel Pipe
    GM889727Courtesy of GENERAL MOTORS CORP.
  8. Remove the rear brake pipe bracket retaining nuts and release the brackets from the body studs.
    9. Fig 3: View Of Rear Brake Pipe Bracket Retaining Nut
    GM890000Courtesy of GENERAL MOTORS CORP.
  9. Release the pipe retainers (1) from the vehicle underbody.
    10. Fig 4: View Of Fuel Hose/Pipe & Retainers At Vehicle Underbody
    GM49888Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel feed pipe from the pipe retainers.
  11. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe.
  12. Remove the fuel feed pipe from the vehicle.
RENDER: 1.0x

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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.