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How to Replace a Fuel Pump in a Saturn Ion

by Contributor; Updated November 07, 2017

Items you will need

  • Fuel pump kit

  • Clamp pliers J43914

  • Sending unit wrench J43827

  • Socket wrench set

  • Torque wrench

How to Replace a Fuel Pump in a Saturn Ion. The Saturn Ion has an electric fuel pump so you should ensure that its fuses and relays are working before inspecting it. You may need to clean or replace your fuel pump if your fuel tank is not empty but your engine is still having trouble getting fuel. The Chevy Cobalt comes in a variety of styles that can affect the replacement fuel pump you choose.

Determine which fuel pump your Saturn Ion will need. This depends not only on the make and model, but also the engine size and type. This model is available with a 2.0 L LSJ supercharged, 2.2 L l61 and 2.4 L LE514 engine.

Prepare your vehicle for fuel pump servicing. Relieve the fuel system pressure and disconnect the negative battery cable with a socket wrench. Disconnect the fuel tank by removing the fuel tank strap bolts with a socket wrench.

Disconnect the fuel lines and hoses from the fuel pump. Remove the retaining ring for the fuel pump with sending unit wrench J43827 and disconnect the retaining clip by pulling it toward the float arm and lifting up.

Pull the fuel pump out of the fuel tank and discard the old fuel tank seal. Remove the feed line from the fuel pump with clamp pliers J43914 and unplug the fuel pump's electrical connector.

Install the new fuel pump using the items included in the kit and be sure to replace the fuel tank seal.

Complete the installation by reversing the removal procedure and tighten the bolts on the fuel tank strap to 18 ft. lbs. with a torque wrench. Start your vehicle to check for leaks.

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