GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra - Mexico 🢒 Engine 🢒 Engine Controls and Fuel - 2.0L (Diesel) 🢒 Fuel Tank Replacement

Removal Procedure

    Caution: Refer to Fuel Pressure Caution in the Preface section.


    Object Number: 1962968 Size: SH
  1. Relieve the fuel pressure. Refer to Fuel Pressure Relief.

    2. Warning: Refer to Battery Disconnect Warning in the Preface section.

  2. Disconnect the negative battery cable.
  3. Drain the fuel tank. Refer to Fuel Tank Draining.
  4. Disconnect the fuel pump connector.
  5. Remove the rear exhaust pipe. Refer to Muffler Replacement.

    6. Object Number: 1962970 Size: SH
  6. Remove the fuel tank filler tube clamp at the fuel tank.
  7. Disconnect the fuel tank filler tube.
  8. Disconnect the fuel vapor line near the fuel tank filler tube.
  9. Disconnect the fuel pump harness connector.

    10. Object Number: 1962972 Size: SH
  10. Disconnect the fuel inlet line and the fuel return line near the right front of the fuel tank.

    11. Object Number: 1962974 Size: SH
  11. Support the fuel tank.
  12. Remove the fuel tank strap retaining nuts.
  13. Remove the hand brake cable retaining nuts.
  14. Remove the fuel tank strap.
  15. Carefully lower the fuel tank.
  16. Remove the fuel tank.
  17. Transfer any parts as needed.

Installation Procedure


    Object Number: 1962974 Size: SH
  1. Raise the fuel tank into position.
  2. Install the fuel tank straps.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the fuel tank strap retaining nuts.

    4. Tighten
    Tighten the fuel tank strap retaining nuts to 20 N·m (15 lb ft).

  4. Install the parking brake cable retaining nuts.

    5. Tighten
    Tighten the hand brake cable retaining nuts to 20 N·m (15 lb ft).


    Object Number: 1962972 Size: SH
  5. Connect the fuel outlet line and the fuel return line.

    6. Object Number: 1962970 Size: SH
  6. Connect the fuel pump harness connector.
  7. Connect the fuel tank filler tube.
  8. Connect the fuel tank vent tube.
  9. Install the fuel tank filler tube clamp at the fuel tank.

    10. Object Number: 1962968 Size: SH
  10. Install the rear exhaust pipe. Refer to Muffler Replacement.
  11. Connect the negative battery cable.
  12. Fill the fuel tank.
  13. Perform a leak check of the fuel tank and the fuel line connections.
  14. Prime the fuel system. Refer to Fuel System Priming.