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Cruze 1 (2008-2016)
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  • Replacing the fuel tank and its filler pipe

Replacing the fuel tank and its filler pipe (Chevrolet Cruze J300)

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If a fuel leak is detected in the tank, it is recommended to replace the tank.

If the fuel pump screen often becomes clogged, remove and flush the tank.

To wash the fuel tank, use detergents "Lobomid", MS or ML. Then, to remove the detergent residue, rinse and steam the tank with a stream of hot water. Dry the tank thoroughly.

It is more convenient to remove an empty tank when working on a lift, overpass or inspection pit. To remove fuel residues remove the fuel module and pump out the fuel through the opened hole in the tank.

You will need: 10 mm and 13 mm wrenches, pliers, and a flat-blade screwdriver.

1. Reduce the pressure in the fuel system (see "Reducing pressure in the engine fuel system").

2. Disconnect the wire from the negative terminal of the battery.

2. Disconnect the wire from the negative terminal of the battery.


3. Unscrew the bolts of the fuel tank mounting clamps on the left and right sides.

Note: For clarity, the work is shown with the additional muffler removed.


Note: For clarity, the work is shown with the additional muffler removed.


4. Using a screwdriver, pry up the plastic fasteners...



4. Using a screwdriver, pry up the plastic fasteners...


5. ...disconnect the fuel tank ventilation hose from the fuel line.

5. ...disconnect the fuel tank ventilation hose from the fuel line.


6. Loosen the filler pipe hose clamp...

6. Loosen the filler pipe hose clamp...


7. ...and remove the hose from the fuel tank pipe.

8. Place a support under the fuel tank.

8. Place a support under the fuel tank.


9. After pressing the clamps, disconnect the fuel pump line and the line to the purge valve of the adsorber.



10. Lower the fuel tank to gain access to the fuel module wiring harness connector.

10. Lower the fuel tank to gain access to the fuel module wiring harness connector.


11. Disconnect the wiring harness connector from the fuel pump module

12. Remove the additional muffler, as it is located under the fuel tank and interferes with its removal.

12. Remove the additional muffler, as it is located under the fuel tank and interferes with its…


13. Carefully lower the fuel tank assembly with the heat shield.

Helpful Hint: Remove the fuel tank with an assistant as it is quite heavy and has an awkward shape to hold.


14. If necessary, remove the fuel tank mounting clamps by removing their pins from the holes in the body panel.

15. Install the fuel tank in the reverse order of removal.

16. After connecting the pipes and the fuel pump wiring harness, fill the tank with gasoline, start the engine and check the tightness of all pipe connections.



If you need to remove filling pipe fuel tank, do the following.

1. Remove the right rear wheel and place the vehicle on a secure support.

2. Disconnect the filler and ventilation hoses from the fuel tank pipes (see pp. 4-7 above in this subsection).

2. Disconnect the filler and ventilation hoses from the fuel tank pipes (see pp. 4-7 above in this…


3. Open the fuel tank filler neck hatch and remove the filler neck (see "Removal and installation the fuel tank filler pipe hatch cover").

3. Open the fuel tank filler neck hatch and remove the filler neck (see «Removal and installation…


4. Unscrew the bolt securing the filler pipe to the side of the body...

4. Unscrew the bolt securing the filler pipe to the side of the body...


5. ...and the bolt securing the lower bracket of the filler pipe to the body.



5. ...and the bolt securing the lower bracket of the filler pipe to the body.


6. Remove the filler pipe assembly with the ventilation hose.

7. Install the fuel tank filler pipe in the reverse order of removal.

The article was checked: Vladimir Romannikov
This article is available at russian, bulgarian, belarusian, ukrainian, serbian, croatian, romanian, polish, slovak, hungarian

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Previous articles
Cruze 1: Supply system
Next articles

Removal, repair and installation of the fuel module
Removal and installation the air filter housing
Replacing the air filter element
Checking the tightness of fuel lines
Decreased pressure in the engine fuel system
Removal and installation the fuel rail
Removal, inspection and installation of injectors
Removal and installation the throttle assembly
Removal and installation the accelerator pedal
Checking and replacing the pneumatic chamber of the intake manifold flap drive


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