Replacing The Fuel Pump In A 1999 Saturn: Step-By-Step Guide

If you're looking to replace the fuel pump in your 1999 Saturn, you'll first need to identify its location. The fuel pump is situated inside the gas tank and will require you to drop the tank, remove the old pump, insert the new one, and then put the gas tank back in place. It's important to replace the gas line hose during this process. Additionally, you should relieve the fuel pressure in the tank and lines, and have a fire extinguisher on hand as a safety precaution. Before undertaking this task, it's advisable to consult a reputable repair guide or seek assistance from a qualified mechanic.

The fuel pump is inside the gas tank

To replace the fuel pump in a 1999 Saturn, you will need to access the fuel pump, which is located inside the gas tank. Here is a step-by-step guide to help you with the process:

Step 1: Relieve Fuel Pressure

Before beginning any work, it is crucial to relieve the fuel pressure in the tank and the fuel lines. This step is essential for safety reasons. Make sure to have a fire extinguisher nearby as an extra precaution.

Step 2: Remove the Gas Tank

To access the fuel pump, you will need to remove the gas tank. Carefully lower the tank and set it aside, ensuring you do not damage any other components.

Step 3: Locate the Fuel Pump

Inside the gas tank, you will find the fuel pump/fuel level sensor assembly. They are usually held in place by a lock ring. Be cautious when handling the assembly as it is delicate.

Step 4: Remove the Old Fuel Pump

Using non-sparking tools, carefully tap the lock ring in a counter-clockwise direction to loosen and remove it. Separate the old fuel pump from the assembly. Be gentle to avoid damaging any components that you intend to reuse.

Step 5: Install the New Fuel Pump

Take the new fuel pump and carefully insert it into the assembly, ensuring it is securely in place. Reattach the lock ring by turning it clockwise, again using non-sparking tools.

Step 6: Reinstall the Gas Tank

Carefully lift the gas tank back into its original position and secure it in place. Ensure all connections are properly attached.

Step 7: Refill the Fuel Line

Before starting the car, allow some time for the fuel line to refill. This step is crucial to ensure the car has sufficient fuel to start and run properly.

It is always recommended to have a reliable reference or a repair manual to guide you through the process. Additionally, checking the fuel pump pressure before replacing the pump is advisable to confirm that it is the source of the issue.

You'll need to drop the gas tank

To replace the fuel pump on a 1999 Saturn, you'll need to drop the gas tank. This is because the fuel pump is located inside the gas tank.

First, locate the fuel tank. It is held in place by straps and bolts. Before you begin, it is recommended that you soak the straps and bolts with a penetrating spray to make them easier to remove.

Next, you will need to disconnect the fuel lines and electrical connections to the fuel pump. Make sure you have a fire extinguisher nearby in case of any accidents. Once everything is disconnected, you can begin to lower the fuel tank.

Use a jack to slowly lower the fuel tank, being careful not to spill any fuel. Once the tank is low enough, you should be able to access the fuel pump. Remove the old fuel pump and insert the new one. Reattach the fuel lines and electrical connections, ensuring everything is secure.

Now, you can raise the fuel tank back into place and reattach the straps and bolts. Make sure everything is secure and lower the vehicle.

Finally, refill the fuel line and start the car to test your new fuel pump.

This process can be complicated, so if you are unsure about any steps or feel uncomfortable performing this task, it is recommended that you seek professional assistance.

Remove the old pump, insert the new one

To replace the fuel pump in a 1999 Saturn, you will need to remove the old pump and insert a new one. Here is a step-by-step guide to help you through the process:

Step 1: Relieve Fuel Pressure

Before starting any work on the fuel system, it is crucial to relieve the fuel pressure in the tank and the fuel lines. This step is essential for safety reasons and should not be skipped. Make sure you have a fire extinguisher nearby as an extra precaution.

Step 2: Remove the Fuel Tank

The fuel pump in a 1999 Saturn is located inside the fuel tank. To access it, you will need to remove the fuel tank. Carefully lower the tank and set it aside, making sure to catch any remaining fuel with an appropriate container.

Step 3: Access the Fuel Pump

With the fuel tank removed, you can now access the fuel pump. It is held in place by a lock ring. Using non-sparking tools, carefully tap the lock ring counter-clockwise to loosen and remove it.

Step 4: Remove the Old Fuel Pump

Once the lock ring is removed, you can take out the old fuel pump. Be careful when handling the old pump, as it may still contain some fuel. Set the old pump aside, making sure to dispose of it properly later.

Step 5: Insert the New Fuel Pump

With the old fuel pump removed, you can now install the new one. Carefully insert the new fuel pump into the fuel tank, making sure it is securely in place. Reattach the lock ring by turning it clockwise with your non-sparking tools until it is tight.

Step 6: Reinstall the Fuel Tank

After confirming that the new fuel pump is securely in place, you can now reinstall the fuel tank. Carefully lift the tank back into position and secure it in place.

Step 7: Refill the Fuel Lines

Before starting the car, you will need to refill the fuel lines. This process may take some time, so be patient and make sure the lines are completely filled before attempting to start the engine.

Step 8: Test the New Fuel Pump

Finally, start the car and test the new fuel pump. Make sure the engine turns over and runs smoothly. If you encounter any issues, recheck your work and ensure that all connections are secure and that the fuel lines are filled.

Remember to consult a repair manual or seek the assistance of a qualified mechanic if you encounter any difficulties during the process. Working on a fuel system can be dangerous, so always put safety first.

Replace the gas line hose

To replace the gas line hose in a 1999 Saturn, you will need to first verify the condition of the fuel hose and gather the necessary tools and materials. Here is a step-by-step guide:

Verifying the Condition of the Fuel Hose:

• Check for any leaking fuel in the engine compartment using a flashlight and a combustible gas detector.
• Inspect the supply, return, and vapor hoses for any fuel leaks.

Gathering the Necessary Tools and Materials:

• Flathead screwdriver
• Fuel hose quick disconnect kit
• Fuel-resistant gloves
• Fuel transfer tank with a pump
• Ratchet with metric and standard sockets
• Wheel chocks
• Floor jack
• Jack stands
• 9-volt battery saver (optional)

Removing the Old Fuel Hose:

Park your vehicle on a flat, hard surface and engage the parking brake. Place wheel chocks around the front tires and raise the vehicle using a floor jack. Place jack stands under the jacking points and lower the vehicle onto them.

If you have a nine-volt battery saver, insert it into your cigarette lighter to keep your computer live and setting current. Otherwise, you can skip this step.

Disconnect the battery by removing the ground cable from the battery's negative post, disabling the power to the ignition and fuel system.

Now, locate and remove the damaged or leaking fuel hose. The process will vary depending on the type of vehicle you have:

For Older Vehicles with a Fuel Hose in the Engine Compartment:

• Remove the hose clamps holding the fuel hose.
• Place a small drip pan under the fuel hose.
• Pull the hose off the attaching fuel line, fuel pump, or carburetor.
• Clean the surface where the fuel hose attaches using a lint-free cloth.

For Older Vehicles with a Fuel Hose Under the Vehicle:

• Remove the fuel hose from the supply side of the fuel pump.
• Go under the vehicle and remove the fuel steel line, which may be held up by rubber grommets.
• Place a transmission jack or similar jack under the fuel tank and remove the fuel tank straps.
• Remove the mounting bolts from the fuel filler neck. You can access these bolts by opening the fuel neck door.
• Lower the fuel tank enough to remove the rubber fuel hose.
• Remove the hose clamp holding the fuel hose and place a drip pan under the fuel tank.
• Detach the fuel hose from the fuel pump and fuel line.

For Vehicles from 1996 to Present with a Fuel Hose in the Engine Compartment:

• Locate the damaged or leaking fuel hose and use a fuel hose quick disconnect tool to remove it from the fuel rail.
• Remove the hose from the fuel line using the quick disconnect tool. This is typically located behind the engine along the firewall.

For Vehicles from 1996 to Present with a Fuel Hose Under the Vehicle:

• Use a fuel hose quick disconnect tool to remove the fuel hose from the fuel line behind the engine along the firewall.
• Go under the vehicle and remove the fuel plastic line, which may be held by rubber grommets.
• If your vehicle has an inline fuel filter, use the quick disconnect tool to remove the fuel line from the fuel filter.
• Place a transmission jack or similar jack under the fuel tank and remove the fuel tank straps.
• Open the fuel neck door and remove the mounting bolts from the fuel filler neck.
• Lower the fuel tank enough to access and remove the plastic fuel hose using a quick disconnect tool.
• Place a drip pan under the fuel tank and remove the fuel hose from the fuel pump.
• If necessary, disconnect the other fuel lines, such as the vapor line from the charcoal canister and the return line from the fuel tank.

Installing the New Fuel Hose:

This process will also vary depending on the type of vehicle.

For Older Vehicles with a Fuel Hose in the Engine Compartment:

• Place new hose clamps around the new fuel hose and ensure they are properly tightened.
• Install the new fuel hose onto the fuel pump, fuel line, or carburetor. Tighten the hose clamps to secure the hose.

For Older Vehicles with a Fuel Hose Underneath:

• Place new hose clamps around the new fuel hose.
• Install the new fuel hose onto the fuel line and fuel pump.
• Raise the fuel tank and snap the fuel line to the fuel filter if your vehicle has one. Ensure all connections are tight.
• Install the mounting bolts to the fuel filler neck, tightening them finger-tight, then an additional 1/8 turn.
• Reattach the fuel tank straps and put Loctite on the threads of the mounting bolts. Tighten the bolts hand-tight, then an additional 1/8 turn to secure the straps.
• Install a fuel line to the fuel pump, ensuring you remove the transmission jack from under the vehicle first.

For Vehicles from 1996 to Present with a Fuel Hose in the Engine Compartment:

• Snap the quick disconnect together onto the fuel line by the firewall.
• Snap the quick disconnect from the fuel line to the fuel rail, ensuring both connections are sealed tight.
• If you removed any brackets, be sure to reinstall them.

For Vehicles from 1996 to Present with a Fuel Hose Underneath:

• Snap the quick disconnect together onto the fuel pump on the fuel tank.
• If installing all three lines, snap the quick disconnect together for the vapor line to the charcoal canister and the return line to the fuel tank.
• Raise the fuel tank and align the fuel filler neck for mounting.
• Install the mounting bolts to the fuel filler neck, tightening them finger-tight, then an additional 1/8 turn.
• Reattach the fuel tank straps and put thread locker on the mounting bolt threads.
• Tighten the bolts hand-tight, then an additional 1/8 turn to secure the straps.
• Snap the quick disconnect on the fuel hose to the fuel line behind the firewall in the engine compartment.
• Ensure you remove the transmission jack.

Checking for Leaks:

Reconnect the ground cable to the battery's negative post and remove the nine-volt battery saver from the cigarette lighter, if you used one. Tighten the battery clamp and ensure a good connection.

Turn the ignition key on and listen for the fuel pump to activate. Turn off the ignition after the fuel pump stops. Cycle the ignition key on and off 3 to 4 times to ensure all fuel lines are full of fuel.

Use a combustible gas detector to check all connections for leaks and sniff the air for any fuel odors.

Lowering the Vehicle:

Raise the vehicle with a floor jack and remove the jack stands. Lower the vehicle so that all four wheels are on the ground, then remove the jack and wheel chocks.

Test Drive:

Drive the vehicle around the block, going over different bumps to allow the fuel to slosh inside the fuel lines. Monitor the dashboard for the fuel level and any engine lights. If the engine light comes on, further diagnosis of the fuel system or an electrical issue may be needed.

Refill the fuel line before starting

When replacing the fuel pump on a 1999 Saturn, it is important to refill the fuel line before starting the car. This is because the fuel pump sits inside the gas tank, and when you drop the gas tank to replace the pump, you will need to refill the fuel line afterward. This process can take some time, so it is important to be patient and not rush the process.

To refill the fuel line, start by locating the fuel line valve. This is usually found near the fuel tank or along the fuel line itself. Once you have located the valve, open it slowly to allow fuel to flow into the line. Be careful not to open the valve too quickly, as this can cause fuel to spray out and create a hazardous situation.

As the fuel line fills, you may need to bleed the line to remove any air bubbles that may be trapped inside. This can be done by opening a bleed screw or valve located on the fuel line or fuel rail. Make sure to have a container ready to catch any fuel that may spill out during this process.

Once the fuel line is filled and any air bubbles have been removed, close the fuel line valve and bleed screw securely. Double-check all connections to ensure they are tight and secure before starting your Saturn.

It is also important to note that you should always refer to the vehicle's repair manual or seek the assistance of a qualified mechanic if you are unsure about any part of the fuel pump replacement or refilling process. Working with fuel and automotive systems can be dangerous if not done properly, so taking your time and following the correct procedures is crucial.

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