Replacing The Fuel Pump In Your Saturn Redline: Step-By-Step Guide

Replacing the fuel pump in a Saturn ION RedLine involves several steps and modifications. The Walbro fuel pump, for example, is longer than the stock pump, requiring adjustments to the fuel sending unit with a Dremel tool. The electrical plug and output side of the pump also need modifications for a proper fit. Additionally, for those converting to a return-style fuel system, the in-tank fuel pressure regulator must be removed. While some online forums provide guidance and pictures for these procedures, professional expertise or further detailed instructions may be necessary for a successful and safe fuel pump replacement.

Removing the fuel tank

To remove the fuel tank from a Saturn Redline, you will need to first jack up the car and secure it with jack stands. Once the car is safely elevated, locate the fuel tank and disconnect the fuel lines and any electrical connections that may be attached to it. Be sure to have a drain pan ready to catch any remaining fuel in the lines. Once all the connections have been disconnected, you can now remove the bolts holding the fuel tank in place. Carefully lower the fuel tank and place it on a safe surface.

At this point, you should also take the opportunity to inspect the fuel tank for any signs of damage or corrosion. It is important to ensure that the fuel tank is in good condition before reinstalling it. Check for any leaks, cracks, or rust spots that may compromise the integrity of the tank. If the tank is damaged, it is crucial to replace it with a new one to avoid potential safety hazards.

Before proceeding with the fuel pump replacement, it is recommended to have a helper assist you with the task. Removing the fuel pump can be a delicate process, and having an extra set of hands can make it easier and reduce the risk of damaging any components. Additionally, having a repair manual specific to your vehicle can be extremely helpful in guiding you through the process.

Now, let's move on to the next steps in removing the fuel pump from your Saturn Redline's fuel tank.

Disconnecting the fuel lines

Locate the Fuel Filter: The fuel filter in a Saturn Redline is located under the rear suspension of the car, towards the passenger rear wheel. Jack up the passenger side of the car and support it with a jack stand to gain access to the fuel filter.

Release the Fuel Pressure: Before disconnecting the fuel lines, it is important to release the fuel pressure. Remove the kick panel to access the fuse box. Remove the fuel pump fuse and start the car. Let the car run until it dies, as this will relieve the fuel pressure.

Undo the Fuel Lines: There are two quick-disconnect plugs on one end of the fuel filter—one light blue and one dark blue. Unplug them by squeezing the coloured sides and pulling them away from the fuel filter. Aim them downwards to drain any remaining fuel into a drain pan.

Use a Fuel Line Quick Disconnect Tool: To disconnect the fuel line from the other side of the fuel filter, use a 3/8" fuel line quick disconnect tool. Slide the tool onto the fuel line and insert it towards the filter to release the prongs holding the filter in place.

Remove the Fuel Filter: Pull the fuel filter off the fuel line. This may require a firm pull as it takes a good amount of force to remove it. Once the fuel filter is removed, put the quick disconnect tool aside.

At this point, you have successfully disconnected the fuel lines from the fuel filter. You can now proceed to install the new fuel filter by sliding it onto the fuel line and reconnecting the quick-connect lines. Remember to re-secure the fuel filter bracket with the 10mm bolt.

It is important to wear safety gear, such as safety glasses and gloves, when performing this task, as fuel can leak and come into contact with your skin or eyes. Additionally, ensure you have a drain pan to catch any spilled fuel.

Removing the old fuel pump

To remove the old fuel pump from your Saturn Redline, you will need to first release the fuel pressure. Remove the kick panel to gain access to the fuse box and take out the fuel pump fuse. Then, start the car and let it run until it dies. Next, undo the gas cap and jack up the passenger side of the car to access the underside of the car. Locate the fuel filter, which is a small, round canister located under the rear suspension towards the passenger rear wheel. Remove the 10mm bolt holding the fuel filter bracket.

There are two quick-disconnect plugs on one end of the fuel filter—one light blue and one dark blue. Unplug them both by squeezing the coloured sides and pulling them off the fuel filter. Aim them downwards to drain any remaining fuel into a drain pan. Take the 3/8" fuel line quick disconnect tool and slide it onto the fuel line on the other side of the fuel filter. Insert it towards the filter to release the prongs holding the filter onto the fuel line. Now, pull the fuel filter off the fuel line—this will require a good amount of force. Once the filter is off, remove the quick disconnect tool.

At this point, you can access the fuel pump, which is located inside the fuel tank. To remove the fuel pump, you will need to drop the fuel tank. This involves removing the bolts holding the tank in place and detaching the fuel lines. Once the tank is lowered, you can access the fuel pump for replacement.

Trimming the fuel sending unit to fit the new pump

Firstly, it is important to note that the Walbro fuel pump is longer than the stock pump, and therefore, some modifications are necessary. The fuel sending unit has an opening where the electrical plug connects to the pump. The housing on the stock pump fits inside this opening, but the housing on the new pump is too large and needs to be adjusted.

Using a Dremel tool, carefully remove some plastic from the new pump's housing to create more room for it to fit inside the opening of the fuel sending unit. Be cautious not to remove too much material at once. It is advisable to trim a little, test the fit, and then trim again as needed until you achieve the perfect fit.

Additionally, the output side of the pump, which connects to the fitting on the top of the sending unit, may also require some trimming. Gently remove the fitting from the top of the sending unit to gain better access for trimming. Again, use a Dremel tool for this task. Remember to remove the rubber seal from the fitting before trimming. There should still be enough room to fit the rubber seal back in place after trimming, so there is no need to trim the seal itself.

Once you have finished trimming and test-fitting, the top of the sending unit should have the housing of the new pump protruding slightly. At this point, you can reconnect the power connector to the pump.

If you are converting to a return-style fuel system, there is one more important step. Before reassembling the fuel sending unit, you must remove the in-tank fuel pressure regulator. To do this, cut the zip tie holding the regulator housing together and remove the cover. Take out the ball bearing and spring-loaded metal tab inside. Reinstall the cover without the zip tie, and then proceed with reassembling the fuel sending unit.

By carefully following these steps, you will be able to successfully trim the fuel sending unit to accommodate the new pump in your Saturn ION RedLine.

Reattaching the power connector and fuel lines

When reattaching the power connector and fuel lines, it is important to be careful and gentle. Begin by reconnecting the power connector to the pump. Then, carefully reattach the fuel lines, ensuring that they are securely connected to the pump.

If you are using a Walbro fuel pump, you will need to make some adjustments to the fuel sending unit for it to fit properly. First, use a Dremel to remove some plastic from the opening where the electrical plug fits on the pump. Then, trim down the fitting that the output side of the pump goes into, again using a Dremel. Test fit the pump after each trim to ensure you don't remove too much material. Once the pump fits securely in the opening, you can reinstall the fuel sending unit into the fuel tank.

If you are reconnecting the fuel lines to a new fuel filter, slide the fuel line onto the new filter until you hear it snap or click into place. Then, attach the two quick-connect lines (one light blue and one dark blue) onto the fuel filter. These lines are different sizes, so you can't mix them up, but remember that the dark blue line goes towards the body of the car, while the light blue line goes towards the ground.

Finally, if you are reattaching the fuel lines to the fuel rail, be sure to spray the injector O-rings with engine oil before reconnecting the lines. This will help prevent leaks and scorch marks.

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