Sylvie Willis
If you need to drop the fuel tank on a 2005 Saturn Ion, you most likely need to replace the fuel pump. Before you start, make sure you have the necessary tools and safety equipment, including eye protection and gloves. You will need to drain the fuel tank and then lower it from the vehicle to access the pump. When you do, check the fuel tank straps and fasteners for excessive corrosion and replace them if necessary. Also, make sure to reinstall and fasten the mounting straps to hold the tank in place.
| Characteristics | Values |
|---|---|
| Reason for dropping the fuel tank | To replace the fuel pump |
| Steps to access the fuel pump | 1. Verify that the fuel pump is faulty. 2. Drain the fuel from the tank. 3. Lower the fuel tank from the vehicle. 4. Remove fuel pump supply and return hoses, EVAP system hoses, and electrical connections to the pump. |
| Considerations when lowering the tank | Check fuel tank straps and fasteners for excessive corrosion and replace if needed. Reinstall and fasten the straps to hold the tank in place. |
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What You'll Learn
- The fuel tank must be removed to replace the fuel pump
- Check for excessive corrosion on the fuel tank straps and fasteners
- Drain the fuel from the tank before lowering it from the vehicle
- Disconnect the fuel pump supply and return hoses
- Reusable brackets and pick-up screens can be attached to a new fuel pump
The fuel tank must be removed to replace the fuel pump
The fuel pump in a 2005 Saturn Ion is located inside the fuel tank. To replace the fuel pump, the fuel tank must be removed from the vehicle to gain access to the pump.
Before removing the fuel tank, the fuel system pressure should be relieved, and the negative battery cable should be disconnected with a socket wrench. The fuel tank strap bolts can then be removed with a socket wrench.
Next, the fuel lines and hoses should be disconnected from the fuel pump. The fuel pump can then be pulled out of the fuel tank, and the old fuel tank seal should be discarded.
After installing a new fuel pump, the fuel tank seal must be replaced. The installation is completed by reversing the removal procedure and tightening the bolts on the fuel tank strap to 18 ft. lbs. with a torque wrench.
It is recommended to keep the gas tank at least a quarter full after installing a new fuel pump to maximize its life.
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Check for excessive corrosion on the fuel tank straps and fasteners
While dropping the fuel tank on a 2005 Saturn Ion, it is important to check for excessive corrosion on the fuel tank straps and fasteners. Corroded fuel tank straps and fasteners can be dangerous and lead to fuel leaks. This is a common issue, especially in older cars and in areas where brines are used on roads to prevent icing. The salt in the brine can corrode the tank, straps, and fasteners, so it is important to regularly inspect them for any signs of corrosion.
To check for corrosion on the fuel tank straps and fasteners of your 2005 Saturn Ion, you will need to get underneath the car and locate the fuel tank. The fuel tank straps are the structural parts that hold the fuel tank in place. Once you have located the straps, carefully inspect them for any signs of rust or corrosion. Pay close attention to the fasteners of the straps, as crevice corrosion in these areas can be particularly dangerous. If the fasteners or straps show signs of excessive corrosion, they will need to be replaced.
You can find standard fuel tank straps and fasteners online or at auto parts stores. However, replacing them can be challenging, as it requires working underneath the car. It may be advisable to seek the help of a professional mechanic for this task.
To prevent corrosion on the fuel tank straps and fasteners, some people have suggested using rubber booties over the ends of the straps to keep moisture out. Others have recommended regularly applying anti-seize grease or super thick grease to the straps and fasteners to prevent rust. Additionally, coating the straps and fasteners with a product like 3M Rust Fighter-1 08892 or Cosmoline can help to protect them from corrosion.
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Drain the fuel from the tank before lowering it from the vehicle
It is important to drain the fuel from your 2005 Saturn Ion's tank before lowering it from the vehicle. This is a relatively simple process that can be done in several ways and will prevent lasting damage to your car's engine. Here is a step-by-step guide on how to do it:
Step 1: Prepare the Workspace
Before you begin, disconnect the negative battery terminals and move your vehicle to a well-ventilated area. This is an important safety precaution as fuel vapours can be harmful to your health when inhaled in large doses. Chock the front wheels to secure them and use a jack to raise the vehicle. Make sure you have enough room to work underneath.
Step 2: Gather the Necessary Tools and Containers
You will need safety gloves, safety glasses, and a jack stand to support your vehicle. Additionally, collect several wide-mouthed containers, such as basins or buckets, to catch the fuel. It is better to have more containers than you need as the capacity of a fuel tank can vary. Ensure these containers are approved for combustible materials and are specifically for fuel storage.
Step 3: Locate the Drain Plug
The drain plug is usually located near the bottom of the fuel tank. It is typically a small bolt screwed directly into the tank. If you see fuel lines, which are small, removable hoses underneath the tank, you can use these as well.
Step 4: Open the Gas Cap and Loosen the Drain Plug
Open the gas cap to release pressure before attempting to loosen the drain plug. Use a ratchet and socket or a wrench to loosen it. As you do so, fuel will start to drain out, flowing into the containers you have placed underneath. Be cautious as fuel might spill due to the force of the flow.
Step 5: Monitor the Draining Process
Keep an eye on the draining process as it can take a long time, especially if you have a full tank. You may need to adjust the gas cap to slow down the flow of fuel. Make sure no fuel is spilled onto the ground to avoid creating a fire hazard.
Step 6: Complete the Process
Once the tank is empty, replace the drain plug tightly. Refill the tank with fresh fuel if you intend to reuse the drained fuel. Otherwise, properly dispose of the drained fuel by contacting your local environmental waste disposal centre or fire department for guidance.
Remember to always make safety a priority when working with fuel, and if you are uncomfortable with any of these steps, seek professional assistance.
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Disconnect the fuel pump supply and return hoses
To disconnect the fuel pump supply and return hoses, you will first need to drain the fuel from the tank. Once the tank is empty, you can start to disconnect the hoses.
Firstly, locate the fuel pump supply and return hoses. These will be connected to the fuel pump, which is located inside the fuel tank. You may need to refer to a repair manual to identify the exact location of the hoses and for any other specific information.
Next, you will need to disconnect the hoses from the fuel pump. This may require some force, as they will be securely attached. Use a suitable tool to carefully pry or loosen the connections. Be cautious not to damage the hoses or any surrounding components.
Once the hoses are disconnected, you may need to cap or plug the openings to prevent any spillage or leakage. Ensure that you have a suitable container or receptacle to catch any residual fuel that may drain from the hoses or fuel pump.
After the hoses are removed, you will need to detach any electrical connections associated with the fuel pump. This will complete the disconnection process for the fuel pump supply and return hoses.
It is important to note that working with fuel and electrical systems can be hazardous. Ensure that you take appropriate safety precautions and refer to expert guidance or seek professional assistance if needed.
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Reusable brackets and pick-up screens can be attached to a new fuel pump
The fuel pump in a car is a hardy piece of equipment that generally provides years of trouble-free service. However, like any other electro-mechanical component, it will eventually degrade and fail. The fuel pump supplies pressurised gasoline to each of the fuel injectors in a car's engine. It is powered by a compact electric motor and is generally located inside the vehicle's fuel tank.
If the fuel pump fails to produce adequate pressure or stops operating, it will need to be replaced. Warning signs of a bad fuel pump include the engine choking or struggling to maintain speed. If these symptoms are ignored, the engine will eventually fail to start.
Once the faulty pump is removed, any reusable brackets and pick-up screens can be attached to the new pump. The pick-up screen is used for fuel filtration inside the fuel tank. The new pump is then installed, and all hoses and electrical connections are re-established. Fuel is added to the tank, and the engine is run to test for leaks.
The average national cost for a fuel pump replacement across all vehicles is roughly between $611 and $894, including parts and labour.
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Frequently asked questions
To drop the fuel tank on a 2005 Saturn Ion, first drain the fuel from the tank. Then, lower the tank from the vehicle to gain access to the fuel pump.
Check the fuel tank straps and fasteners for excessive corrosion and replace them if necessary.
If you don't replace the straps and fasteners, the tank will not be reliably held in place.
After installing a new fuel pump, keep the gas tank at least a quarter full to maximize the life of the new pump.
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