GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra - Mexico 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Fuel Tank Replacement

Removal Procedure

    Warning: Refer to Relieving Fuel Pressure Warning in the Preface section.


    Object Number: 1376114 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. Remove the front muffler. Refer to Muffler Replacement.

    5. Object Number: 1376117 Size: SH
  5. Disconnect the fuel tank filler tube.

    6. Object Number: 1376118 Size: SH
  6. Disconnect the fuel line near the right front of the fuel tank.

    7. Object Number: 1376119 Size: SH
  7. Remove the rear seat. Refer to Rear Seat Cushion Replacement.
  8. Remove the fuel pump access cover.

    9. Object Number: 1376120 Size: SH
  9. Disconnect the electrical connector at the fuel pump assembly.
  10. Disconnect the fuel line.

    11. Object Number: 1376121 Size: SH
  11. Remove the parking brake cables support bracket bolt.
  12. Remove the parking brake cables from the fuel tank.

    13. Object Number: 1376122 Size: SH
  13. Disconnect the fuel vapor line from the solenoid valve.

    14. Object Number: 1376127 Size: SH
  14. Support the fuel tank.
  15. Remove the fuel tank strap retaining nuts.
  16. remove the fuel tank strap.
  17. Carefully lower the fuel tank.
  18. Remove the fuel tank.
  19. Transfer any parts as needed.

Installation Procedure

    Object Number: 1376121 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).


    Object Number: 1376122 Size: SH
  4. Connect the fuel vapor line from the solenoid valve.

    5. Object Number: 1376121 Size: SH
  5. Install the parking brake cables support bracket.
  6. Install the parking brake cables from the fuel tank.

    7. Object Number: 1376120 Size: SH
  7. Connect the fuel line.
  8. Connect the electrical connector at the fuel pump assembly.

    9. Object Number: 1376119 Size: SH
  9. Install the fuel pump access cover.
  10. Install the rear seat. Refer to Rear Seat Cushion Replacement.

    11. Object Number: 1376118 Size: SH
  11. Connect the fuel line near the right front of the fuel tank.

    12. Object Number: 1376117 Size: SH
  12. Connect the fuel tank filler tube.
  13. Install the fuel tank filler tube clamp at the fuel tank.

    14. Object Number: 1376114 Size: SH
  14. Install the front muffler. Refer to Muffler Replacement.
  15. Connect the negative battery cable.
  16. Fill the fuel tank.
  17. Perform a leak check of the fuel tank and the fuel line connections.

Removal Procedure

    Warning: Refer to Relieving Fuel Pressure Warning in the Preface section.


    Object Number: 1376119 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

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


    Object Number: 1376120 Size: SH
  2. Disconnect the negative battery cable.
  3. Remove the rear seat. Refer to Rear Seat Cushion Replacement.
  4. Remove the fuel pump access cover.
  5. Disconnect the electrical connector at the fuel pump assembly.
  6. Disconnect the fuel line.

    7. Object Number: 1376129 Size: SH
  7. Remove the fuel pump assembly clip.
  8. Remove the fuel pump assembly from the tank.

Installation Procedure

    Object Number: 1376129 Size: SH
  1. Clean the gasket mating surface on the fuel tank.
  2. Position the new gasket in place.
  3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and connector installation.

    4. Object Number: 1376120 Size: SH
  4. Install the fuel pump assembly clip.
  5. Connect the fuel pump assembly connector.
  6. Install the fuel pump line.

    7. Object Number: 1376119 Size: SH
  7. Install the fuel pump access cover.
  8. Connect the negative battery cable.
  9. Perform an operational check of the fuel pump.
  10. Install the rear seat. Refer to Rear Seat Cushion Replacement.