GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 SL 🢒 Body and Accessories 🢒 Body Rear End 🢒 Fuel Tank Filler Door Replacement

Removal Procedure

    Object Number: 866864 Size: SH

    Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

  1. Open the fuel filler door.
  2. Remove the 2 bolts holding the door to the quarter panel.
  3. After removing the fuel filler door from the quarter panel, remove the fuel fill cap tether from the door hinge by pushing the tabs together with your fingers and sliding through the hole in the hinge.

Installation Procedure

    Object Number: 866864 Size: SH
  1. Attach the fuel fill cap to the fuel filler door by snapping the end of the tether retainer into the hole in the door on the hinge.
  2. Position the fuel filler door to the quarter panel. Align as necessary.

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

  3. Install the 2 bolts holding the door to the quarter panel.

    4. Tighten
    Tighten the fuel filler door-to-quarter panel fasteners to 2.5 N·m (22 lb in).