Cruze

Fuel Tank Replacement

Special Tools

EN 807 Closure Plugs

For equivalent regional tools, refer to Special Tools : 1.6L LXT .

Warning: Refer to Petrol/Petrol Vapours Warning in the Preface section.

Warning: Refer to Actions to Take When Working with Fuel Warning in the Preface section.

Warning: Refer to Safety Goggles and Fuel Warning in the Preface section.

1. Open the bonnet.

Warning: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

For Vehicles equipped with OnStar® (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is On or with RAP activated may cause activation of the OnStar® Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.
2. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Remove the right rear tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
5. Raise the vehicle by its half height. Refer to Lifting and Jacking the Vehicle .
6. Install the rear wheel housing liner panel. Refer to Rear Wheelhouse Panel Liner Replacement .



7. Disconnect the to fuel tank harness in-line connector (1).
8. Raise the vehicle by its half height.




Warning: Do not breathe the air through the EVAP component tubes or hoses. The fuel vapours inside the EVAP components may cause personal injury.

9. Remove the clamp (2).
10. Remove the fuel tank filler hose (3) from the fuel tank filler pipe (1).

Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution in the Preface section.




11. Disconnect the fuel tank filler vent pipe connector (6).
12. Install the EN 807 plug into the fuel tank vent pipe.
13. Disconnect the 2 fuel tank pipe connectors (3).
14. Install the EN 807 plugs into the 2 fuel tank pipes.

Warning: To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack.

Caution: When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result.

15. Place a suitable adjustable jack under the fuel tank.
16. Remove the 2 fuel tank strap bolts (4).
17. Remove the 2 fuel tank straps (5).

Note: 2. mechanic Required.

Note: Retract jack.

18. Remove fuel tank.

Note: 2. mechanics required.

Note: Extend jack.

1. Install fuel tank.
2. Install the 2 fuel tank straps (5).
3. Install the 2 fuel tank strap bolts (4).
4. Remove the EN 807 plugs from the 2 fuel tank pipes.
5. Connect the 2 fuel tank pipe connectors (3).
6. Remove the EN 807 plug from the fuel tank vent pipes.
7. Connect the fuel tank filler vent pipe connector (6).



8. Install the fuel tank filler hose (3) to the fuel tank filler pipe (1).
9. Install the clamp (2).
10. Lower the vehicle by its half height.



11. Connect the to fuel tank harness in-line connector (1).
12. Install the rear wheel housing liner panel. Refer to Rear Wheelhouse Panel Liner Replacement .
13. Lower the vehicle by its half height.
14. Install the right rear tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .
15. Refill the fuel tank. Refer to Fuel Tank Draining .
16. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection .
17. Close the bonnet.