Replacing The Fuel Pump In A Saturn Sl2: Step-By-Step Guide

If you're experiencing problems with your 2000 Saturn SL2, such as sudden bursts of acceleration or a faulty fuel pump, you may need to consider replacing it. The fuel pump is located inside the fuel tank, and you will need to remove the fuel tank to access it unless there is an access panel in the trunk or under the back seat. This is a complex task that requires advanced knowledge of automotive repair, specifically fuel and exhaust systems.

To replace the fuel pump, you will need to relieve the fuel pressure system by removing the fuel cap and raising your Saturn with a jack. You will also need to disconnect the negative cable from the battery and siphon any remaining fuel from the tank. Once the tank is empty, you can remove it and take out the old fuel pump. Finally, insert the new fuel pump, reassemble the fuel tank, and reconnect the negative cable to the battery.

Locating the fuel pump

The fuel pump is a small, cylindrical part jutting from the fuel line, accompanied by mounts on both sides and a valve on the tank side. The fuel line bends at a 90-degree angle as it approaches the motor carriage.

• Remove the rear seat of the vehicle.
• Look for an access panel in the trunk or under the back seat. If there is an access panel, remove it to access the fuel pump.
• If there is no access panel, you will need to remove the fuel tank. Place a bucket under the fuel tank to catch any leftover fuel.
• Follow the fuel line from the tank to the pump. The fuel line bends at a 90-degree angle as it approaches the motor carriage.
• Locate the small, cylindrical part jutting from the fuel line, with mounts on both sides and a valve on the tank side. This is the fuel pump.

Disconnecting the electrical connection

Before beginning any work on your vehicle, it is important to ensure your safety. Put on protective gear, such as gloves and eye protection, and make sure you are working in a well-ventilated area. It is also crucial to refer to your car's user manual for any model-specific instructions or variations.

Now, to begin the process of disconnecting the electrical connection:

• Locate the electrical connection on the fuel pump. It is secured by a simple bolt.
• Using a 12 mm socket wrench, loosen and remove the bolt that secures the electrical connection.
• Once the bolt is removed, carefully set it aside in a safe place to ensure it is not lost or misplaced.
• With the bolt removed, you should now be able to gently pull and disconnect the electrical connection from the fuel pump.
• It is important to note that there may be some residual fuel or pressure in the lines, so be cautious and have a bucket or container ready to catch any drips or spills.
• If there is a clip or clamp holding the electrical connection in place, be sure to release or remove it carefully before completely detaching the connection.
• Once the electrical connection is disconnected, set it aside with the bolt, ensuring that it is kept separate from any fuel or oily components.

At this point, you have successfully disconnected the electrical connection from the fuel pump of your 2000 Saturn SL2. Remember to refer to your car's repair manual for any additional steps or variations specific to your vehicle's make and model. Always exercise caution when working on your vehicle, especially when dealing with electrical components and fuel systems.

Removing the old fuel pump

To remove the old fuel pump from your 2000 Saturn SL2, you will first need to relieve the fuel pressure system. Remove the fuel cap to equalize the pressure in the fuel tank. Next, remove the negative cable from the battery.

Now, raise your Saturn with a jack and support it with jack stands. Remove the fuel tank from under your car. The tank must be as empty as possible, so you may need to siphon out the remaining fuel.

Pinch together the legs of the retainers on the supply and return fuel lines with a pair of needle-nose pliers. Pull the fittings from the fuel pump/level sensor module. Use a shop rag to soak up any spilled fuel.

Mark the fuel pump and the fuel tank to indicate its exact position in the tank. Make sure these indicators align. Unscrew the module's locknut counter-clockwise with a large pair of channel locks. You may need to loosen the locknut using a hammer and a brass (not steel) punch.

Take out the module through the mounting hole, being careful not to abruptly pull on the module, as you could break off the float or float arm into the fuel tank.

Finally, check the O-ring seal on the mounting flange and replace it if it is damaged.

Installing the new fuel pump

To install the new fuel pump, follow these steps:

Firstly, mark the new fuel pump/level sensor module in the same areas you marked the old module to indicate its position in the fuel tank. Then, carefully install the new fuel pump/level sensor module into the mounting hole of the fuel tank. Ensure that you do not harm the fuel inlet strainer, float arm, and float while inserting the module. Line up the markings you made on the module and fuel tank.

Next, install and screw on the module's locknut. Tighten it down with your channel locks. After this, connect the fuel supply and return lines to the module. Check that they are secure on the module by lightly twisting and tugging them.

Then, install the fuel tank back under your Saturn. Pour the fuel from the gas can into the filler hole and install and tighten the fuel cap. Reconnect the negative cable on the battery.

Finally, remove the jack stands and lower your Saturn.

Reattaching the electrical connection

To reattach the electrical connection of the fuel pump in a 2000 Saturn SL2, follow these steps:

• Ensure that the new fuel pump is securely in place and the bolt sides are tightened with a crescent wrench.
• Reattach the electrical connection using a 12 mm socket wrench. This connection is secured with a simple bolt, so tighten it accordingly.
• Open the gas valve behind the pump using the crescent wrench.
• Climb out from under the vehicle.
• Release the parking brake and drive the car off the car ramps.

By following these steps, you will have successfully reattached the electrical connection for the fuel pump in your 2000 Saturn SL2.

Frequently asked questions