GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Bonneville 🢒 Body 🢒 Body Rear End 🢒 Fuel Tank Filler Door Replacement

Removal Procedure

    Object Number: 255993 Size: SH
  1. Open the fuel filler door.
  2. Remove the fasteners securing the fuel filler door to the vehicle.
  3. Remove the fuel filler door from the quarter panel.

Installation Procedure

    Object Number: 255993 Size: SH
  1. Install the fuel filler door.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the fasteners securing the fuel filler door to the vehicle.

    3. Tighten
    Tighten the fasteners to 9 N·m (66 lb in).

  3. Close the fuel filler door.

    4. Object Number: 644290 Size: SH
  4. Check the fuel filler door for acceptable gap (A). An equal 3 +/- 1 mm (0.12 +/- 0.04 in) around the entire perimeter.
  5. Adjust fuel filler door required.
  6. Verify the proper operation of the fuel filler door.