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Home >> Saturn >> 2008 >> Astra XE, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
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Removal Procedure

    IMPORTANT:
    • 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, saleable container.
  1. Open the hood.
    2. CAUTION: Refer to Battery Disconnect Caution .
  2. Remove the battery.
    • Disconnect the ground clamp from ground terminal.
    • Loosen the nut.
  3. Loosen the nuts on the right rear wheel.
  4. Raise the vehicle halfway.
  5. Remove the right rear wheel.
    6. Fig 1: View Of Wheel Housing Inner Paneling Nuts And Bolts
    GM1937706Courtesy of GENERAL MOTORS CORP.
  6. Remove the wheel housing inner paneling, right rear.
    • Remove the 2 nuts (1).
    • Remove the 2 bolts (2).
    7. Fig 2: View Of Wiring Harness Of The Pressure Sensor, Wiring Harness Plug And Cable Ties
    GM1998419Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the wiring harness of the pressure sensor (atmospheric pressure) (1).
    • Remove the wiring harness plug (2).
    • Remove the 3 cable ties (3).
  8. Raise the vehicle halfway.
    9. Fig 3: View Of Wiring Harness Of The Pressure Sensor, Fuel Filler Tube And Cable Ties
    GM1998420Courtesy of GENERAL MOTORS CORP.
  9. Remove the wiring harness of the pressure sensor (atmospheric pressure) (1) from the fuel filler tube (2).

    Remove the 3 cable ties (3).

  10. Remove the complete exhaust system. Refer to Exhaust System Replacement .
    11. Fig 4: View Of Wiring Harness Plug Of The Fuel Tank Fuel Pump Module
    GM1998421Courtesy of GENERAL MOTORS CORP.
  11. Remove the wiring harness plug of the fuel tank fuel pump module (1).
    12. Fig 5: View Of Vent Pipe, Quick-Release Fitting And Vent Hose
    GM1998422Courtesy of GENERAL MOTORS CORP.
  12. Remove the vent hose (3) from the vent pipe (1).

    Disconnect the quick-release fitting (2) using SA9805E  /KM-796-A. See Special Tools .

    13. Fig 6: View Of Fuel Filler Tube From The Fuel Tank Clamp
    GM1998423Courtesy of GENERAL MOTORS CORP.
  13. Remove the fuel filler tube from the fuel tank.

    Release the clamp (1).

    14. Fig 7: View Of Middle Fuel Line, Rear Fuel Lines And Release Fittings
    GM1998424Courtesy of GENERAL MOTORS CORP.
  14. Remove the rear fuel lines (3, 5) from the middle fuel lines (1, 2)
    • Disconnect the 2 quick-release fittings.
    • Press to release (4).
    15. Fig 8: View Of Parking Brake Cable From The Bracket
    GM1998425Courtesy of GENERAL MOTORS CORP.
  15. Remove the parking brake cable from the bracket (1) in 7 places.
  16. Retract the jack.
    17. Fig 9: Identifying Fuel Tank Holding Straps Bolts
    GM1998427Courtesy of GENERAL MOTORS CORP.
  17. Remove the 2 fuel tank holding straps.

    Remove the 4 bolts (1).

    18. IMPORTANT: The wiring harness must be passed over the rear axle.
  18. With the aid of an assistant, remove fuel tank.
    19. Fig 10: View Of Fuel Tank Attaching Parts
    GM1998428Courtesy of GENERAL MOTORS CORP.
  19. fuel tank attaching parts:
    • Evaporative emission canister (1)
    • Rear vent line (2)
    • Vent line from fuel tank to carbon canister (3)
    • Vent line from rear purge valve (4)
    • Rear fuel supply line (5)
    • Fuel tank fuel pump module (6)
    • Pressure sensor fuel tank (7)
    • Fuel tank (8)
    • Vent line to fuel filler pipe (9)
    • Wiring harness (10)
    • Rear purge valve (11)
    • Vent line from evaporative emission canister to rear purge valve (12)
    20. Fig 11: View Of Evaporative Emission Canister, Rear Purge Valve And Rear Vent Line
    GM1998429Courtesy of GENERAL MOTORS CORP.
  20. Remove the evaporative emission canister (1).
    • Remove the vent line from the fuel tank to the evaporative emission canister (2).

      Disconnect the quick-release fitting.

    • Remove the vent line from the evaporative emission canister to the rear purge valve (4).

      Disconnect the quick-release fitting.

    • Remove the rear vent line (3).

      Disconnect the quick-release fitting.

    • Release the bracket and remove the evaporative emission canister (arrows).
  21. Remove the rear vent line from the bracket.
  22. Remove the rear purge valve (1).
    • Remove the vent line from the evaporative emission canister to the rear purge valve (2).

      Disconnect the quick-release fitting.

    • Remove the vent line from the rear purge valve.

      Disconnect the quick-release fitting.

    • Remove the wiring harness from the rear purge valve (3).

      Remove the wiring harness plug.

    • Release the bracket and remove the rear purge valve (arrows).
  23. Remove the 2 vent lines (2, 4) from the bracket.
    24. Fig 12: View Of Vent Line From The Fuel Tank To Evaporative Emission Canister And Quick-Release Fittings
    GM1998431Courtesy of GENERAL MOTORS CORP.
  24. Remove the vent line from the fuel tank to evaporative emission canister (1).

    Disconnect the quick-release fittings (2).

    25. Fig 13: View Of Rear Fuel Supply Line, Quick-Release Fittings And Bracket
    GM1998435Courtesy of GENERAL MOTORS CORP.
  25. Remove the rear fuel supply line (1).
    • Disconnect the quick-release fittings (2).
    • Remove the rear fuel supply line from the bracket (3).
    26. Fig 14: View Of Quick-Release Fitting And Vent Line To The Fuel Filler Pipe
    GM1998436Courtesy of GENERAL MOTORS CORP.
  26. Remove the vent line to the fuel filler pipe (2).

    Disconnect the quick-release fitting (1).

    27. Fig 15: View Of Wiring Harness Of The Fuel Tank Fuel Pump Module And Pressure Sensor Fuel Tank
    GM1998439Courtesy of GENERAL MOTORS CORP.
  27. Remove the wiring harness of the fuel tank fuel pump module (4).
    • Remove the wiring harness plug of the fuel tank fuel pump module (2).
    • Remove the wiring harness plug of the pressure sensor fuel tank (3).
    • Remove the wiring harness from the bracket in 4 places (1).
    28. Fig 16: View Of Fuel Tank Fuel Pump Module Cover And Retaining Ring
    GM1998440Courtesy of GENERAL MOTORS CORP.
  28. Remove the fuel tank fuel pump module cover using J 45722  /KM-J-45722. See Special Tools .
    • Rotate the retaining ring (1) counterclockwise.
    • Remove the gasket.
    29. Fig 17: View Of Fuel Tank Fuel Pump Module
    GM1998441Courtesy of GENERAL MOTORS CORP.
    CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
    IMPORTANT: Remove the fuel tank fuel pump module carefully upward.
  29. Remove the fuel tank fuel pump module from the fuel tank.

    Remove the gasket.

  30. Remove the heat shield.

    Remove the 3 nuts.

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