GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 Astra 🢒 Engine 🢒 Engine Controls and Fuel - 1.8L (2H0) 🢒 Evaporative Emission Canister Replacement

Special Tools

SA9805E /KM-796-A Fuel Line Separator

Removal Procedure

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

    Caution: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.

    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, sealable container.

  1. Open the hood.

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

  2. Remove the battery.
    3. • Disconnect the ground clamp from the ground terminal.
    • Remove the nut.
  3. Loosen the nuts on the right rear wheel.
  4. Raise the vehicle halfway.
  5. Remove the right rear wheel.

    6. Object Number: 1937706 Size: SH
  6. Remove the wheel housing inner panelling, right rear.
    7. • Remove the 2 nuts (1).
    • Remove the 2 bolts (2).

    Object Number: 1998419 Size: SH
  7. Remove the wiring harness from the pressure sensor (atmospheric pressure) (1).
    8. • Remove the wiring harness plug (2).
    • Remove the 3 cable ties (3).
  8. Raise the vehicle halfway.

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

    10. Remove the 3 cable ties (3).

  10. Remove the complete exhaust system. Refer to Exhaust System Replacement .

    11. Object Number: 1998421 Size: SH
  11. Remove the wiring harness plug of the fuel tank fuel pump module (1).

    12. Object Number: 1998422 Size: SH
  12. Remove the vent hose (3) from the vent pipe (1).

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


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

    14. Release the clamp (1).


    Object Number: 1998424 Size: LH
  14. Remove the rear fuel lines (3, 5) from the middle fuel lines (1, 2).
    15. • Disconnect the 2 quick-release fittings.
    • Press release (4).

    Object Number: 1998425 Size: LF
  15. Remove the parking brake cable from the bracket (1) in 7 places.
  16. Retract the jack.

    17. Object Number: 1998427 Size: LH
  17. Remove the 2 fuel tank holding straps.

    18. Remove the 4 bolts (1).

    Important: The wiring harness must be passed over the rear axle.

  18. With the aid of an assistant, remove fuel tank.

    19. Object Number: 1998429 Size: LH
  19. Remove the evaporative emission canister (1).
    20. • 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).

Installation Procedure
  1. Install the evaporative emission canister.
    2. • Install the evaporative emission canister at the bracket.
    • Install the rear vent line.
    • Connect the quick-release fitting.
    • Install the vent line at the evaporative emission canister to the rear purge valve.
    • Connect the quick-release fitting.
    • Install the vent line at the fuel tank to the evaporative emission canister.
    • Connect the quick-release fitting.
  2. With the aid an assistant, position the fuel tank.

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

  3. Install the 2 fuel tank holding straps.

    4. Tighten
    Tighten the 4 fuel tank holding strap bolts to 23 N·m (17 lb ft).

  4. Extend the jack.
  5. Install the parking brake cable to the bracket in 7 places.
  6. Connect the rear fuel lines to the middle fuel lines.

    7. Connect the 2 quick-release fittings.

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

    8. Tighten
    Tighten the fuel filler tube to fuel tank clamp to 3.5 N·m (31 lb in).

  8. Install the vent hose to the vent pipe.

    9. Connect the quick-release fittings.

  9. Connect the wiring harness plug of the fuel tank fuel pump module.
  10. Install the complete exhaust system. Refer to Exhaust System Replacement .
  11. Connect the wiring harness of the pressure sensor (atmospheric pressure) to the fuel filler tube.

    12. Install the 3 cable ties.

  12. Lower the vehicle halfway.
  13. Install the wiring harness of the pressure sensor (atmospheric pressure).
    14. • Install the wiring harness plug.
    • Install the 3 cable ties.
  14. Install the wheel housing inner paneling, right rear.

    15. Tighten

        • Tighten the 2 wheel housing inner paneling nuts to 2.5 N·m (22 lb in).
        • Tighten the 2 wheel housing inner paneling bolts to 2.5 N·m (22 lb in).
  15. Mount the right rear wheel.
  16. Lower the vehicle halfway.
  17. Install the right rear wheel.

    18. Tighten
    Tighten the right rear wheel to 110 N·m (81 lb ft).

  18. Connect the battery.

    19. Connect the ground clamp to the ground terminal.

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

  19. For programming procedures, refer to Control Module References .
  20. Close the hood.