Inspection and Installation
INSPECT GRADE VENT VALVE AND FUEL TANKIMPORTANT: The date code on grade vent valve is very small and can be difficult to see. Using a flashlight and magnifying glass may aid in date code identification.
1. Inspect top of grade vent valve for a date code of "1119," "1119A," or "1119B."
^ If the date code on grade vent valve is "1119," "1119A," or "1119B," fuel tank assembly must be replaced.
^ If the date code on grade vent valve is NOT "1119," "1119A," or "1119B," fuel tank should be re-installed in vehicle.
2. If date code on grade vent valve is not "1119," "1119A," or "1119B" and fuel tank is going to be re-installed in vehicle, inspect fuel tank for fuel tank-to-body insulator pad.
^ If fuel tank-to-body insulator pad is present and properly located, install fuel tank in vehicle.
^ If fuel tank-to-body insulator pad is NOT present and a replacement pad is not available, obtain fuel tank-to-body insulator pad by calling the Saturn Parts Assistance Center at 1-800-828-2112, prompt 2.
INSTALL FUEL TANK
IMPORTANT: There are two types of fuel tank assemblies that SSPO will be sending to Retailers. Both types are under the same part number. The tank assemblies differ in the fact that one tank has a rubber shim on the top of the tank covering the fuel line coming from the fuel pump and going to the fuel filter. The other tank incorporates a design change and does not require the addition of the rubber shim. Both types of tanks are being used to replace suspect fuel tank assemblies.
Both types of tank assemblies will have a sticker on front of them identifying whether the rubber shim is required. The first four digits of the code on the sticker will read either "LS31" or "LS32."
- LS31 indicates that tank DOES require rubber shim.
- LS32 indicates that tank DOES NOT require rubber shim. Tanks requiring rubber shim will have rubber shim already installed from SSPO.
1. When installing a replacement fuel tank, remove plastic fuel line retainers on fuel feed line, fuel return line, and recirc line from old tank and install them into female portions of fuel line connections on vehicle. The replacement tank will come with a new retainer on the EVAP canister purge line.
2. With aid of an assistant, position fuel tank under vehicle.
3. Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts to underbody.
Torque: 20 N.m (15 ft-lbs)
4. Connect fuel tank electrical connector.
NOTICE: Care must be taken to ensure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
IMPORTANT: Lubricate male end of filter with clean engine oil to ease installation.
5. Connect fuel feed, fuel return, and EVAP canister purge lines between tank and chassis fuel bundle.
6. Install fuel tank strap bracket.
Torque: 10 N.m (89 in-lbs)
7. Install fuel tank grounding strap attachment nut from stud located near fuel filter.
Torque: 4.5 N.m (40 in-lbs)
IMPORTANT: Ensure that [1][2]EVAP vent solenoid pipe is installed in position on filler pipe bracket.
8. Loosely install filler pipe lower bracket attachment screw but do not tighten.
IMPORTANT: To ease installation, lightly wipe the outside of the fuel tank inlet connector with water.
9. Install fill neck to fuel tank.
NOTICE: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6 mm (1/4 in.) of the end of the connector hose.
10. Tighten hose clamp on filler pipe to fuel tank connecting hose.
Torque: 5 N.m (44 in-lbs)
11. Connect EVAP canister vent pipe to canister vent hose at quick connect and recirc line at quick connect.
12. Tighten lower attachment screw on filler pipe to underbody.
Torque: 13 N.m (9.5 ft-lbs)
13. Install heat shield.
Torque: 7 N.m (62 in-lbs)
14. Install intermediate pipe (with muffler).
Torque: 20 N.m (15 ft-lbs)
15. Lower vehicle.
16. Add fuel to fuel tank.
17. Connect negative battery cable.
Torque: 17 N.m (13 ft-lbs)
18. Prime fuel system.
a. Using ignition, cycle switch On for 5 seconds and then Off for 10 seconds. Repeat this twice.
b. Examine fuel lines for leaks.
c. Crank engine until it starts (allowing a maximum of 15 seconds of cranking time).