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Home >> Saturn >> 2008 >> Astra XR, 2D Hatchback, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Pressure Sensor Replacement >> Removal Procedure

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. Disconnect the battery.
    • Disconnect the ground clamp from negative battery 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 right rear wheel housing inner panel.
    • 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 from the pressure sensor (atmospheric pressure) (1)
    • Disconnect 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. Disconnect the wiring harness of 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. Disconnect the wiring harness plug from 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 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 Pressure Sensor Fuel Tank, Wiring Harness Plug Of The Pressure Sensor Fuel Tank And Bracket
    GM1998453Courtesy of GENERAL MOTORS CORP.
  19. Remove the pressure sensor fuel tank (1).
    • Disconnect the wiring harness plug of the pressure sensor fuel tank (2).
    • Carefully pull upward from bracket (3).
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