How to Replace the Fuel Tank Filler Neck on a 2009 Impala

The Impala started in 1959 as the highest trim level available on the Chevy Bel Air, but became its own model the following year. Through the 1960s, the Impala became the best-selling vehicle in Chevys lineup, thanks in part to its high-performance SS trim level. The Impala lasted through 1984, and Chevy cut it from the lineup in 1985 after emission restrictions in the 1970s and 1980s killed its power output. Chevy brought back the Impala in 2000. The 2009 Impala came in five trim levels -- LS, LT, LT2, LTZ and SS. Replacing the filler neck on the 2009 Impala involves replacing the entire fuel filler tube, as it is one assembly.

Instructions

Removal

1

Open the hood and remove the lid from the under-hood fuse block. Remove the fuel pump fuse -- the fuse located on the right-rear corner of the fuse block.

2

Unscrew the oil filler cap and pull upward firmly on the engine cover to disengage its retaining clips. Set the engine cover aside. Tighten the oil filler cap.

3

Find the fuel service port on the rear passenger side of the fuel rail assembly. Unscrew the fuel service port cap. Insert a small flathead screwdriver into the service port until it contacts the metal valve inside the port. Wrap the service port and screwdriver with a thick shop towel, then push downward on the screwdriver to open the valve, relieving fuel pressure. Remove the screwdriver and towel, then tighten the fuel service port cap.

4

Open the fuel filler door and unscrew the fuel filler cap. Remove the screws securing the fuel filler pipe to the fuel filler pocket using a ratchet and socket.

5

Lift the rear of the Impala with a floor jack and slide jack stands under the rear suspension crossmember. Lower the vehicle onto the jack stands.

6

Trace the fuel filler pipe until you find the bracket connecting it to the underbody. Remove the bolt securing the bracket. Pull the evaporative emissions hose, the small rubber hose, from the bracket.

7

Find where the vent tube, the small tube on top of the fuel filler pipe, connects to the fuel tanks vent tube. Press and hold the ears on the fitting securing the two hoses together and separate the two hoses.

8

Continue tracing the fuel filler pipe until you find where it connects to the fuel tank. Loosen the hose clamp securing the fuel filler hose to the fuel tank using a ratchet and socket, then pull the fuel filler pipe from the fuel tank.

9

Lower the fuel filler pipe and remove it from the vehicle.

Installation

10

Lift the new fuel filler pipe into place under the Impala, guiding the upper end of the hose into its hole in the rear quarter-panel. Press the lowest end of the pipe onto the inlet on the fuel tank and tighten the hose clamp to 22 inch-pounds with an inch-pound torque wrench and a socket.

11

Press the vent tube on top of the fuel filler pipe into the vent tube on the fuel tank until you hear the quick-connect fitting snap into place.

12

Press the evaporative emission hose back into its slot in the fuel filler pipes bracket. Align the fuel filler pipe brackets bolt hole with the bolt hole in the Impalas underbody, then hand-thread the brackets bolt. Tighten the brackets bolt to 115 inch-pounds.

13

Raise the Impala off the jack stands with the floor jack and remove the jack stands. Lower the Impala to the ground.

14

Thread the fuel filler pipe-to-fuel filler pocket screws by hand, then torque them to 22 inch-pounds. Tighten the fuel filler cap onto the fuel filler tube.

15

Remove the oil filler cap. Line up the engine cover retaining clips with their slots on top of the engine, then press the engine cover downward to lock it into place. Tighten the oil filler cap.

16

Press the oil pump fuse back into its receptacle in the under-hood fuse block, then close the fuse blocks lid and close the Impalas hood.

17

Cycle the key from Off to Run two or three times, then start the vehicle. Check for any leaks.