GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2000 🢒 L300/LW300 🢒 Engine 🢒 Engine Controls - 3.0L (L81) 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 894302 Size: SH

    Caution: 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.

  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. Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  2. Position the vehicle on a hoist.

    3. Object Number: 891510 Size: SH

    Caution: 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.

  3. Disconnect the negative battery cable.

    4. Notice: 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.

  4. Relieve the fuel system pressure. Refer to Fuel System Pressure Relief.

    5. Object Number: 892450 Size: SH
  5. Raise the vehicle to a comfortable working position.
  6. Remove the exhaust system intermediate pipe, with muffler.
  7. Remove the rear heat shield retaining bolts.

    8. Object Number: 893228 Size: SH
  8. Remove the fuel filler pipe lower bracket attachment screw.

    9. Object Number: 892352 Size: SH

    Caution: 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.

  9. Disconnect the EVAP canister vent hose.
  10. Loosen the fuel filler pipe hose clamp closest to the fuel tank
  11. Disconnect the quick connect at the recirc line.

    12. Important: If there are more than 11.4 liters (3 gallons) of fuel in the tank, insert a suitable siphon hose into the tank filler neck and remove the remaining fuel into a certified handling cart.

  12. Disengage the filler pipe hose from the fuel tank.

    13. Object Number: 892353 Size: SH
  13. Remove the tank grounding strap attachment nut located near the fuel filter.
  14. Remove the fuel tank strap bracket, protecting the fuel line connections between the fuel tank and chassis fuel bundle.

    15. Object Number: 892344 Size: SH

    Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.

  15. Disconnect the fuel feed line after the fuel filter.
  16. Disconnect the fuel return and EVAP canister purge lines between the tank and chassis fuel bundle.
  17. Disconnect the fuel tank electrical connections.
  18. Loosen the front tank strap bolts, but do not remove.
  19. With the aid of an assistant, remove the 2 rear tank retaining strap bolts.
    20. 19.1. Lower the rear half of the tank and slide the fuel tank down and out rearward.
    19.2. Remove the fuel tank from the vehicle.

Installation Procedure

    Important: There were 2 types of fuel tank assemblies used during early production of L-Series vehicles. 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 tank assemblies will have a label on the front vertical surface of the tank. This label will be used to determine whether the rubber shim is required. It will be necessary to lift the plastic fuel tank out of the metal fuel tank heat shield to see this label. The first 4 digits of the serial number on the label will be LS27, LS30, LS31, or LS32.


    Object Number: 885843 Size: SH
  1. LS27, LS30, or LS31 indicates that the tank DOES require a rubber shim.

    2. Object Number: 885846 Size: SH
  2. LS32 indicates that the tank DOES NOT require a rubber shim.

    3. Object Number: 885842 Size: MF
  3. The above illustration shows the location of the fuel tank mounting shim.
    4. 3.1. If the fuel tank code is LS27, LS30, or LS31, obtain a service replacement fuel tank mounting shim, P/N 21019723, and install on the fuel tank at the location indicated in the above illustration.
    3.2. If the fuel tank code is LS32, no fuel tank shim is required.

    Object Number: 892353 Size: SH
  4. With the aid of an assistant, position the fuel tank under the vehicle.
  5. Attach the electrical connectors to the fuel pump and tank pressure sensor.
  6. Reposition the fuel tank mounting straps and shield around the tank and install the strap mounting bolts to the underbody.

    7. Notice: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

  7. Install the new retainers into the female portion of the quick-connect fittings on the underbody fuel and EVAP canister purge lines.

    8. Important: Lubricate the male ends of the filter with clean engine oil to ease installation.

  8. Connect the fuel feed return and upper lines.
  9. Install the fuel tank grounding attachment nut located near the fuel filter.

    10. Tighten
    Tighten the fuel tank grounding attachment nut to 4.5 N·m (40 lb in).


    Object Number: 893228 Size: SH

    Important: Ensure that the EVAP vent solenoid pipe is installed in position on the filler pipe bracket.

  10. Loosely install the filler pipe lower bracket attachment screw, but do not tighten.

    11. Object Number: 893316 Size: SH
  11. Install the fill neck to fuel tank.

    12. Important: 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.

  12. Tighten the hose clamp on the filler pipe to fuel tank connecting hose.

    13. Tighten
    Tighten the fuel fill neck-to-fuel tank clamp to 5 N·m (44 lb in).


    Object Number: 892767 Size: SH
  13. Connect the EVAP canister vent pipe at the quick connect to canister vent hose.
  14. Tighten the lower attachment screw on the filler pipe to underbody.

    15. Tighten
    Tighten the fuel fill pipe-to-body (lower) to 13 N·m (115 lb in).

  15. Install the heat shield.

    16. Tighten
    Tighten the rear heat shield to 8 N·m(69 lb in).


    Object Number: 885839 Size: SH
  16. Install the fuel tank strap bracket.

    17. Tighten
    Tighten the fuel tank stone guard-to-body to 10 N·m (89 lb in).


    Object Number: 891510 Size: SH
  17. Install the intermediate pipe, with muffler.
  18. Add the fuel and connect the negative battery cable.
  19. Prime the fuel system.
    20. 19.1. Using the ignition, cycle the switch ON for 5 seconds and OFF for 10 seconds. Repeat this twice.
    19.2. Examine the fuel lines for leaks.
    19.3. Crank the engine until it starts, allowing a maximum of 15 seconds of cranking time.