Space Frame Exposed in Fuel Filler Neck Area

Customers may comment about space frame being exposed in fuel filler neck area when fuel filler door is in the open position.

The opening in rear quarter panel for fuel neck is larger than panel filler (grommet) at rear most position. This creates a gap between rear edge of fuel filler neck and rear edge of quarter panel cutout area. This gap exposes the space frame structure when fuel filler door is open.

Remove current design panel filler (Grommet) and replace with new design panel filler (grommet) (P/N 21112201) following the procedure in this bulletin.

Caution: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO OPPOSITE END OF VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.

1. Position vehicle on hoist.
2. Open fuel filler cap and old style quarter outer panel filler (grommet) around fuel filler neck.



3. Remove fuel filler cap and old style quarter outer panel filler (grommet) around fuel filler neck. (Sedan shown. Coupe similar).
4. Remove fuel filler neck attachment screw at upper end of neck.
5. Raise vehicle to a comfortable working position.
6. Remove inner wheelhouse liner.
7. Remove fuel filler neck lower bracket attachment bolt at underbody left side rail.

Important: When installing new quarter outer panel filler (grommet ) around fuel filler neck with other hand from outside to aid in installation.

8. Lower vehicle and move fuel filler pipe to the rear of the opening in the quarter panel cutout area. Starting with the front portion of the new quarter panel filler (P/N 21112201) begin installing filler around the fuel filler neck and underneath quarter panel. The hole in the new quarter outer panel filler is to be located at the 6 o'clock or bottom of cutout area for proper installation.
9. At the location of the upper fuel filler pipe attachment screw, pull just enough of the filler out from under the quarter panel and over the top of the fuel filler pipe. Insert a fat blade screwdriver inside fuel filler neck opening between panel filler (grommet) and filler neck edge to hold panel filler (grommet) in place while installing upper attachment screw.
10. Raise vehicle and install fuel filler neck lower bracket attachment bolt. (Sedan shown. Coupe similar.)

Tighten
Tighten the bracket to 8 N·m (71 lb in.)

11. Lower vehicle and install fuel filler neck upper bracket attachment screw.

Tighten
Tighten the bracket to 3.5 - 4.5 N·m (31 lb in).

12. Carefully remove screwdriver that was previously installed and route panel filler (grommet) over top of fuel filler neck.
13. Use a blunt end object, such as plastic tool, to carefully push remaining portion of panel filler (grommet) underneath edge of quarter panel being careful not to cut panel filler (grommet).

Important: Go through opening wheelhouse with one hand to pull panel filler (grommet) while pushing with the other hand from the outside to aid with installation of the remaining portion of panel filler (grommet).

14. Install fuel cap and close fuel filler door.
15. Install inner wheelhouse liner.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn dealer system as follows: