GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Engine 🢒 Engine Controls and Fuel - 1.6L (LDE) and 1.8L (2H0) 🢒 Fuel Tank Filler Evaporative Emission Pipe Replacement

Removal Procedure

    Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section.

    Note: 

       • The fuel tank must be drained with a suitable, commercially-available fuel removal unit and suction hose - follow safety regulations and national legislation. The fuel tank is fitted with a refill limit float valve. This is located on the filler neck in the fuel tank. To prevent damaging the refill limit float valve, a suitable suction hose must be used.
       • In the presence of fuel vapors or escaping fuel - observe safety regulations and national legislation. Store drained fuel in a suitable, sealable container.

  1. Open the hood.

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

  2. Disconnect the battery.
    3. 2.1. Disconnect the ground clamp from the ground terminal.
    2.2. Loosen the nut.
  3. Raise the vehicle all the way.

    4. Object Number: 1998446 Size: LH
  4. Remove the fuel filler pipe.
    5. 4.1. Open the fuel filler door.
    4.2. Remove the fuel filler pipe gas cap (1).

    Remove the bolt (4).

    4.3. Remove the rubber cover (2).
    4.4. Remove the bolt (5).
    4.5. Install the fuel filler pipe gas cap.
  5. Raise the vehicle halfway.
  6. Remove the right rear wheel.

    7. Object Number: 1937706 Size: SH
  7. Remove the right rear wheel housing inner paneling.
    8. 7.1. Remove the 2 nuts (1).
    7.2. Remove the 2 bolts (2).

    Object Number: 1998420 Size: SH
  8. Remove the wiring harness of the pressure sensor (atmospheric pressure) (1) from the fuel filler tube (2).

    9. Remove the 3 cable ties (3).


    Object Number: 1998423 Size: SH
  9. Remove the fuel filler tube from the fuel tank.

    10. Release the clamp (1).


    Object Number: 1998463 Size: SH
  10. Remove the fuel filler tube (1) from the fuel filler pipe.

    11. Release the clamp.

Installation Procedure
  1. Install the fuel filler tube to the fuel filler pipe.

    2. Fasten the clamp.

    Caution: Refer to Fastener Caution in the Preface section.

  2. Install the fuel filler tube to the fuel tank.

    3. Tighten
    Fasten the clamp to 3.5 N·m (31 lb in).

  3. Install the wiring harness of the pressure sensor (atmospheric pressure) to the fuel filler tube.

    4. Install the 3 cable ties.

  4. Install the right rear wheel housing inner paneling.

    5. Tighten

        • Tighten the 2 nuts to 3 N·m (26 lb in).
        • Tighten the 2 bolts to 3 N·m (26 lb in).
  5. Install the right rear wheel.
  6. Lower the vehicle halfway.

    7. Tighten
    Tighten the right rear wheel to 10 N·m (89 lb in).

  7. Install the fuel filler pipe.
    8. 7.1. Remove the fuel filler pipe cap.

    Tighten
    Tighten the bolt to 6 N·m (53 lb in).

    7.2. Install the rubber cover.
    7.3. Install the fuel filler pipe cap.

    Tighten
    Tighten the bolt to 6 N·m (53 lb in).

  8. Lower the vehicle all the way.
  9. Connect the battery.

    10. Connect the ground clamp to the ground terminal.

    Tighten
    Tighten the ground clamp nut to 5 N·m (44 lb in).

  10. For programming procedures, refer to Control Module References.
  11. Close the hood.