Replacing Fuel Pump In Saturn Relay: Step-By-Step Guide

The fuel pump is a crucial component of your car's fuel system, delivering fuel from the tank to the fuel injectors. If your 2005 Saturn Relay is experiencing issues such as trouble starting, stalling, or unusual noises from the fuel tank, you may need to replace the fuel pump. This can be done by following a series of steps, including disconnecting the battery, locating and removing the old fuel pump, installing a new one, and testing the vehicle for proper fuel pump operation. The average cost for this replacement ranges from $846 to $2403, depending on labour and parts.

Disconnect the battery

Disconnecting the battery is an important first step when replacing the fuel pump in a 2005 Saturn Relay. This is a safety measure to reduce the chance of a fire. Here is a detailed, step-by-step guide on how to disconnect the battery:

Step 1: Caution: Batteries generate hydrogen gas, which is extremely flammable and may explode if ignited by a spark or flame. Battery acid is also extremely corrosive and can cause severe injury if it comes into contact with skin or eyes. Therefore, exercise extreme caution when handling the battery.

Step 2: Remove the underhood electrical center cover and mounting bolts.

Step 3: Disconnect the negative battery cable first. This is an important safety precaution to prevent any accidental sparks or electrical shorts.

Step 4: Loosen the positive battery cable nut and remove the cable from the battery. Always remove the negative cable first and reconnect it last to prevent any accidental shorts or sparks.

Step 5: Remove the battery hold-down retainer bolt and retainer. Be careful not to tip the battery more than 40 degrees during this process.

Step 6: Carefully remove the battery, ensuring that it is lifted straight up and out of the battery tray.

By following these steps, you will have successfully disconnected the battery in your 2005 Saturn Relay, allowing you to proceed with the fuel pump replacement safely.

Remove the fuel pump relay

To remove the fuel pump relay from your 2005 Saturn Relay, first turn the ignition key to the 'run' position and listen for the fuel pump to actuate. You should also listen for any buzzing or clicking noise from the fuel pump relay. Next, start the engine and check that there is oil pressure—you will know there is oil pressure when the oil light indicator goes out. Park your vehicle on a flat, hard surface and make sure that the transmission is in park (for automatics) or in first gear (for manuals). Place wheel chocks around the front tires and engage the parking brake to lock the rear tires from moving.

Install a nine-volt battery saver into your cigarette lighter to keep your computer live and keep your settings current. Then, open the vehicle's hood and disconnect your battery by taking the ground cable off the battery's negative post, disabling the power to the fuel pump and sending unit.

Locate the fuse box in the engine compartment and remove the cover. Some fuse boxes are held on with hex screws or bolts and require a ratchet to remove them, while others are held on with clips. Using the diagram on the fuse box cover, locate the fuel pump relay. If your fuse box cover does not have any diagrams, refer to your owner's manual for the engine compartment fuse box diagram.

Install the new fuel pump relay

Now that you've removed the old fuel pump relay, it's time to install the new one. Here's a step-by-step guide:

Part 2 of 4: Installing the new fuel pump relay

Step 1: Install the new relay into the fuse box the same way the old relay was removed. Ensure that the new relay is placed in the correct orientation.

Step 2: Put the fuse box cover back on and snap it into place. If you had to remove screws or bolts to access the fuse box, be sure to reinstall them without over-tightening, as this can strip them.

Step 3: Remove the fuel cap from the fuel tank and then put it back on, ensuring a good seal. This step is important as it ensures that the fuel system fully pressurizes properly when the fuel pump is activated.

Now that you've installed the new fuel pump relay, it's time to check if it's operating correctly and take the vehicle for a test drive.

Part 3 of 4: Checking for fuel pump relay operation

Step 1: Reconnect the ground cable back to the battery's negative post, and tighten the battery clamp to ensure a good connection. If you used a nine-volt battery saver, remove it from the cigarette lighter.

Step 2: Turn the ignition key on and listen for the fuel pump to activate. Turn off the ignition after the fuel pump stops making noise. Repeat this process a few times to ensure the fuel rail is full of fuel prior to starting the engine.

Step 3: Turn the key to start and start up the engine. Monitor how long the starter is engaged during the cranking period. Most modern vehicles will not start until oil pressure has built up.

Step 4: Remove the wheel chocks from the wheels.

Part 4 of 4: Test drive the vehicle

Step 1: Drive the vehicle around the block and listen for any unusual noises from the fuel pump or fuel pump relay. Accelerate the engine quickly to ensure the fuel pump is functioning correctly.

Step 2: Monitor the dashboard for any engine warning lights. If the check engine light comes on, further diagnosis of the fuel pump assembly or an electrical issue within the fuel system may be required. If the problem persists, seek assistance from a certified technician.

Check for fuel pump relay operation

To check for fuel pump relay operation, you must first locate the fuel pump relay in your vehicle's fuse box. The main fuse box is typically found underneath the hood, near the front of your car. However, there may also be a smaller fuse box beneath the steering column inside the car. After locating the fuse box, remove its cover and consult the diagram printed on it to identify the fuel pump relay's position. Typically, the fuel pump relay is coloured green or grey.

Once you have located the fuel pump relay, pull it straight out from the fuse box. Grab the relay firmly on both sides and pull it directly up and out from the terminals. If it doesn't come out smoothly, try rocking it back and forth gently to loosen the connection. Please note that your engine won't start without the fuel pump relay, so avoid removing it if you plan on driving the vehicle.

If you suspect that the fuel pump relay is faulty, you can test it by using a multimeter to check the resistance in the relay's circuit. First, locate the circuit diagram on the relay, which will indicate which prongs to connect the power and multimeter to. Typically, the "power" prongs are labelled 85 and 86, while the prongs to be tested are labelled 87 and 30.

Set your multimeter to the ohm setting (Ω) and attach jumper wires to the terminals of your vehicle's battery. Connect one jumper wire to the positive terminal and the other to the negative terminal. Then, flip the relay over so the prongs point upward, and attach the jumper wires to the corresponding prongs. You should hear a clicking sound when you attach the second wire, indicating that the relay is functioning.

Finally, hold the multimeter probes against the remaining two prongs on the relay. If the circuit inside the relay is functioning properly, the multimeter should display a reading of 0, indicating no resistance between the points. If the reading is greater than 0, the circuit inside the relay is faulty and should be replaced.

Test drive the vehicle

Once you've replaced the fuel pump in your 2005 Saturn Relay, it's important to test drive the vehicle to ensure that the new fuel pump is functioning correctly and there are no issues. Here's a step-by-step guide on how to do it:

Start the Engine:

Before you hit the road, start the engine and let it run for a few minutes. Listen for any unusual noises and check for any signs of fuel leaks. If everything seems normal and there are no leaks, you can proceed to the next step.

Short-Distance Drive:

For the initial test drive, choose a route that is relatively short and doesn't involve high speeds or long distances. This is a precautionary measure in case there are any unexpected issues with the new fuel pump. Drive the vehicle at varying speeds, including slow and moderate paces, to get a sense of how the engine is performing.

Observe Engine Behaviour:

During the test drive, pay close attention to how the engine behaves. Notice if there are any unusual sounds, vibrations, or performance issues. A properly functioning fuel pump should provide a consistent flow of fuel to the engine, resulting in smooth acceleration and stable idling. Make sure the engine doesn't stall or sputter, which could indicate a problem with the fuel delivery.

Check for Warning Lights:

Keep an eye on the dashboard to ensure that no warning lights illuminate during the test drive. Specifically, watch out for the "check engine" light, as it could indicate a problem with the fuel system or other issues. If any warning lights come on, pull over to a safe location and address the issue.

Vary Driving Conditions:

During the test drive, try to simulate different driving conditions as much as possible. This includes driving on flat roads, uphill, and downhill slopes. Also, try accelerating to different speeds and then slowing down to observe how the engine responds to these changes. A well-functioning fuel pump should allow the engine to adjust smoothly to these varying conditions.

Monitor Fuel Efficiency:

While the test drive route may not be your usual commute, try to keep track of the vehicle's fuel efficiency. Compare it to the fuel efficiency you typically achieve with your Saturn Relay. If there is a significant discrepancy, it could indicate that the fuel pump is not delivering fuel efficiently, or there may be other issues with the engine or fuel system.

Extended Test:

If the initial short-distance drive goes well and you don't observe any issues, consider taking an extended test drive. This could involve driving on highways, longer distances, or more challenging terrain. The goal is to push the vehicle a bit further to ensure that the fuel pump performs reliably under various conditions and for extended periods.

Post-Drive Inspection:

After each test drive, whether short or extended, park the vehicle and perform a final inspection. Check the engine bay and under the vehicle for any signs of fuel leaks. Also, inspect the fuel lines and connections to ensure that everything is secure and intact. If you notice any leaks or loose connections, address them immediately.

By following these steps and being vigilant during the test drive, you can help ensure that your newly replaced fuel pump is functioning correctly and your 2005 Saturn Relay is safe and reliable for everyday use. Remember always to put your safety first and address any concerns or unusual behaviours promptly.

Frequently asked questions