For 1990-2009 cars

# Malfunction Indicator Lamp (MIL)/Check Engine Light On, DTCs P0442, P0455, P0456 Set (Diagnose and Replace Fuel Fill Cap and Filler Pipe, If Necessary)

Subject: | Malfunction Indicator Lamp (MIL)/Check Engine Light On, DTCs P0442, P0455, P0456 Set (Diagnose and Replace Fuel Fill Cap and Filler Pipe, if Necessary)

Models: | 2008 Saturn Astra

| Built Prior to and Including VIN Breakpoint 85108201

This bulletin is being revised to provide VIN breakpoint and update the part number for the fuel tank filler pipe. Please discard Corporate Bulletin Number 08-06-04-024 (Section 06 -- Engine/Engine Propulsion).

### Condition

Some customers may comment that the check engine light is on.

Upon investigation, the technician may find one or more of the following DTCs set as current or history in the engine control module.

• | P0442

• | P0456

• | P0455

### Cause

This condition may be caused by a poor seal between the fuel filler pipe and the fill cap.

### Correction

Follow published SI diagnostics for the DTC encountered. Refer to the Evaporative Emission System Diagnosis for detailed instructions on system testing. If the leak is detected at the fuel tank filler pipe and fill cap area, replace both the fuel fill cap and filler pipe as a pair. DO NOT replace just the fill cap or filler pipe as a repeat DTC may occur. Use the procedure listed below.

1. Remove the fuel fill cap.
2. Remove the fuel fill cap retaining strap screw.
3. Raise and support the vehicle.
4. Remove the right rear tire/wheel assembly.
5. Remove the right rear wheelhouse liner.
6. Remove the fuel tank filler pipe seal.
7. Remove the fuel tank filler pipe screw from the fuel tank fill pipe housing.
8. Remove the fuel tank filler pipe bolt from the underbody side rail.
9. Remove the three tie-straps securing the wiring harness to the filler pipe.
10. Disconnect the electrical connector from the pressure sensor (atmospheric pressure).
11. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting from the fuel tank vent pipe.
12. Loosen the fuel filler pipe hose clamp at the fuel tank.
13. Separate the fuel filler pipe hose from the fuel tank.
14. Remove the fuel tank filler pipe.
15. Transfer the pressure sensor (atmospheric pressure) to the new fuel filler pipe.
16. Install the fuel tank filler pipe.
17. Install the fuel filler pipe hose to the fuel tank.
18. Connect the fuel tank fill EVAP emission pipe quick connect fitting from the fuel tank vent pipe.
19. Tighten the fuel filler pipe hose clamp at the fuel tank.
20. Install the fuel tank filler pipe bolt to the underbody side rail.
21. Connect the electrical connector to the pressure sensor (atmospheric pressure).
22. Install the three tie-straps.
23. Install the fuel tank filler pipe screw to the fuel tank filler pipe housing.
24. Install the fuel tank filler pipe seal.
25. Install the right rear wheelhouse liner.
26. Install the right rear tire/wheel assembly.
27. Install the fuel fill cap retaining strap screw.
28. Install the new fuel fill cap.
29. Inspect for leaks.

### Parts Information

Part Number | Description
--- | ---
94731452 | Cap, Fuel Fill
94702398 | Pipe, Fuel Tank Filler

### Warranty Information

For vehicles repaired under warranty, use:

Labor Operation | Description | Labor Time
--- | --- | ---
L9716* | Replace Fuel Tank Fill Pipe and Cap | 0.7 hr
Add | Diagnosis Time | 0.0-0.3 hr
*This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.