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Fuel Tank: Installation

  1. With aid of an assistant, position fuel tank with heat shield and straps under vehicle.
    Fig 1: Positioning Fuel Tank, Heat Shield And Straps
    G01019398Courtesy of GENERAL MOTORS CORP.
  2. Attach electrical connectors to fuel pump and tank pressure sensor.
  3. Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts to underbody. Tighten fuel tank mounting strap to 20 N.m (15 ft-lbs).
    NOTE: Replace plastic fuel line retainers whenever fuel supply lines are disconnected. Install new retainer into female portion of connection. Care must be taken to ensure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
  4. Install a new retainers into female portion of quick-connect fitting on underbody fuel and EVAP canister purge lines.
    NOTE: Lubricate male ends of filter with clean engine oil to ease installation.
  5. Connect fuel feed, return and vapor lines.
  6. Install fuel tank grounding strap attachment nut located near fuel filler neck. Tighten fuel tank grounding strap attachment to 4.5 N.m (35 in-lbs).
    NOTE: Ensure that EVAP vent solenoid pipe is installed in position on filler pipe bracket.
  7. Loosely install filler pipe lower bracket attachment screw but do not tighten. See Figure .
  8. Install fill neck to fuel tank.
    NOTE: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6 mm (1/4 in.) of the end of the connector hose.
  9. Tighten hose clamp on filler pipe to fuel tank connecting hose. Tighten fuel fill neck-to-fuel tank clamp to 5 N.m (44 in-lbs). See Figure .
  10. Connect EVAP canister vent pipe at quick connect to canister vent hose. See Figure .
  11. Tighten lower attachment screw on filler pipe to underbody. Tighten fuel fill pipe-to-body (lower) to 13 N.m (9.5 ft-lbs).
  12. Install heat shield. Tighten rear heat shield to 7 N.m (52 in-lbs).
  13. Install fuel line stone chip guard. Tighten fuel line stone chip guard to 12 N.m (106 in-lbs). See Figure .
  14. Install intermediate pipe (with muffler). See Figure .
  15. Add fuel and connect negative battery cable. Tighten battery terminal bolts to 17 N.m (13 ft-lbs).
  16. Prime fuel system.
    1. Using ignition, cycle switch On for five seconds and then Off for 10 seconds. Repeat this twice.
    2. Examine fuel lines for leaks.
    3. Crank engine until it starts (allowing a maximum of 20 seconds of cranking time).
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