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Home >> Saturn >> 2009 >> Vue Green Line, 2.4 Z >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 2.4L - Introduction >> Repair Instructions >> Fuel Tank Replacement (AWD) >> Removal Procedure

Removal Procedure

WARNING: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.
WARNING: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.
  1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the exhaust system. Refer to Exhaust Muffler Replacement (LAT or LE5) or Exhaust Muffler Replacement (LZ4) or Exhaust Muffler Replacement (LY7) or Exhaust Muffler Replacement (LCS) .
  5. Remove the propeller shaft. Refer to Propeller Shaft Replacement .
    6. Fig 1: Fuel Tank Fuel Feed Line Quick Connect Fitting
    GM1884595Courtesy of GENERAL MOTORS CORP.
    WARNING: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.
    CAUTION: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.
  6. Remove the evaporative emission canister. Refer to Evaporative Emission Canister Replacement .
  7. Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis fuel feed line (2), if necessary. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the fresh air tube quick disconnect (3).
    9. Fig 2: Fill Pipe Vent Line Quick Connect Fitting
    GM1884596Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fill pipe vent line quick connect fitting (4) from the fuel tank fresh air line (3). Refer to Plastic Collar Quick Connect Fitting Service .
  10. Disconnect the fuel tank vapor line quick connect fitting (2) from the fill pipe recirculation line (5). Refer to Plastic Collar Quick Connect Fitting Service .
  11. Loosen the fuel fill pipe hose clamp (1) at the fuel tank.
  12. Remove the fuel fill pipe (6) hose from the fuel tank.
  13. Remove the rear parking brake cable to frame rail bolts. Unclip parking brake cables from fuel tank straps, and reposition parking brake cables to provide clearance for fuel tank removal.
    14. Fig 3: Fuel Tank Straps And Nuts
    GM1884597Courtesy of GENERAL MOTORS CORP.
  14. Using a suitable adjustable jack, support the fuel tank.
    15. CAUTION: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.
  15. Remove the fuel tank strap nuts (2) and straps (1).
    16. NOTE: It is not necessary to remove the rear drive module (RDM) in order to remove the fuel tank.
  16. Using the adjustable jack, slowly lower and reposition the fuel tank (3) in order to remove the tank from the vehicle. Using the adjustable jack, slowly lower the front of the fuel tank. Pull the fuel tank forward to clear the rear drive module (RDM) and remove the fuel tank assembly with shield from the vehicle.
  17. If replacing the fuel tank perform the following steps, otherwise proceed to the Installation Procedure.
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