GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 L300/LW300 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Filler Tube Replacement

Removal Procedure

    Object Number: 892351 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. Ensure that the fuel level in tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining .

    2. Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  2. Position the vehicle on the hoist.
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  4. Remove the fuel filler cap and rubber closeout grommet around the fuel filler pipe neck, inside the fuel filler door.
  5. Remove the attachment screw at the upper end of filler pipe.
  6. Raise the vehicle to a comfortable working position.
  7. Remove the wheel house inner liner.
  8. Disconnect the wiring harness connector at the EVAP canister vent solenoid.

    9. Object Number: 892352 Size: SH
  9. Remove the fuel filler pipe lower bracket attachment screw.
  10. Disconnect the EVAP canister hose.
  11. Loosen the fuel filler pipe hose clamp closest to the fuel tank.
  12. Disengage the filler pipe hose from the fuel tank and remove the fuel filler pipe.

Installation Procedure

    Object Number: 892407 Size: SH
  1. Raise the vehicle to comfortable working height.

    2. Important: To ease installation, lightly wipe the outside of the fuel tank inlet connector with plain water.

  2. Position the filler pipe into the wheel opening with the top of the pipe within the body panel opening.
  3. Install the fuel filler pipe into the fuel tank opening.

    4. Important: Ensure that the EVAP vent solenoid pipe is installed in position on the filler pipe bracket.

  4. Loosely install the filler pipe lower bracket attachment screw, but do not tighten.

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


    Object Number: 892351 Size: SH
  5. Lower the vehicle and install the filler pipe upper bracket attachment screw.

    6. Tighten
    Tighten the fuel fill pipe-to-body (upper) to 2.5 N·m (22 lb in).

  6. Install the rubber closeout grommet to the body and filler pipe.
  7. Install the fuel cap.
  8. Raise the vehicle to a comfortable working height.

    9. Object Number: 893316 Size: SH

    Important: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6 mm (1/4 in) of the end of the connecting hose.

  9. Tighten the hose clamp on the filler pipe to fuel tank connecting hose.

    10. Tighten
    Tighten the fuel fill neck-to-fuel tank clamp to 5 N·m (44 lb in).


    Object Number: 892767 Size: SH
  10. Connect the EVAP canister vent pipe at the quick connect to canister vent hose.
  11. Connect the recirculation line (5/16 in) quick connection.
  12. Tighten the lower attachment screw on the filler pipe to the underbody.

    13. Tighten
    Tighten the fuel fill pipe-to-body (lower) to 13 N·m (9.5 lb ft).

  13. Connect the harness connector to the EVAP vent solenoid.
  14. Install the wheelhouse inner liner to the wheel opening.
  15. Connect the negative battery cable.

    16. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).