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Home >> Cadillac >> 2009 >> STS V >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 4.4L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

  1. Install the primary and secondary fuel tank modules if previously removed. Refer to Primary Fuel Tank Module Replacement  and Secondary Fuel Tank Module Replacement .
    2. NOTE: Ensure the following are properly routed while raising the fuel tank:
    • The fuel tank wiring harness
    • The EVAP wiring harness
    • The EVAP hoses at the EVAP canister
    • The fuel/EVAP hoses at the chassis pipes
    Fig 1: View Of Fuel Tank Straps
    GM785806Courtesy of GENERAL MOTORS CORP.
  2. With the aid of an assistant, carefully raise the fuel tank to the vehicle, aligning the filler neck with the filler hose.
    3. NOTE: Ensure the fuel tank straps are not pressed into the fuel tank.
  3. Carefully bend the fuel tank straps back to their original form.
  4. Position the fuel tank straps around the rear frame and upward into position, aligning the holes in the straps with the threaded holes in the chassis.
    5. CAUTION: Refer to Fastener Caution .
  5. Install the fuel tank strap bolts and tighten to 50 N.m (37 lb ft).
    6. Fig 2: Identifying Fuel Filler Hose To Fuel tank
    GM785808Courtesy of GENERAL MOTORS CORP.
  6. Connect the filler hose (1) to the fuel tank. Tighten the fuel filler tube hose clamp (3) to 3.5 N.m (31 lb in).
  7. Connect the filler vent tube (2) to the EVAP hose. Refer to Plastic Collar Quick Connect Fitting Service .
    8. Fig 3: Identifying EVAP Hoses At EVAP Canister
    GM785817Courtesy of GENERAL MOTORS CORP.
  8. Connect the EVAP hoses to the EVAP canister.
  9. Insert the retainer into the chassis and press inward on the tab to engage.
  10. Connect the fuel tank pressure sensor electrical connector to the EVAP canister.
  11. Connect the electrical connector to the EVAP canister vent solenoid valve.
    12. Fig 4: View Of Fuel Tank Electrical Connector
    GM801228Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel tank electrical connector.
    13. Fig 5: Identifying Fuel Filter
    GM1653564Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel feed hoses (4 and 5) to the fuel filter. Refer to Metal Collar Quick Connect Fitting Service .
  14. Connect the EVAP hose (6) to the chassis bundle. Refer to Plastic Collar Quick Connect Fitting Service .
    15. Fig 6: View Of Screw Jack Under Rear Frame
    GM801226Courtesy of GENERAL MOTORS CORP.
  15. Raise the rear frame using the screw jack.
  16. Install the 2 front bolts to the rear frame and tighten to 265 N.m (195 lb ft).
  17. Remove the screw jack.
    18. Fig 7: Identifying Left Side Rear Suspension Bracket Brace
    GM1614625Courtesy of GENERAL MOTORS CORP.
  18. Swing the left side rear suspension bracket brace into position and install the bolt (1) and tighten to 160 N.m (118 lb ft).

  19. Tighten the rear suspension bracket brace nut to 85 N.m (63 lb ft).
    20. Fig 8: Identifying Fuel Filter
    GM1653564Courtesy of GENERAL MOTORS CORP.
  20. Swing the right side rear suspension bracket brace into position and install the bolt (7) and tighten to 160 N.m (118 lb ft).
  21. Tighten the rear suspension bracket brace nut (8) to 85 N.m (63 lb ft).
    22. Fig 9: Identifying Support Fixture Components
    GM708375Courtesy of GENERAL MOTORS CORP.
  22. Position the screw jack (3) under the lower control arm in order to raise the lower control arms.
  23. Install the lower shock bolts (2) and tighten to 150 N.m (111 lb ft).
  24. Remove the screw jack (3).
  25. Install the propeller shaft. Refer to Rear Propeller Shaft Replacement (AWD) or Rear Propeller Shaft Replacement (RWD) .
  26. Install the exhaust system. Refer to Exhaust System Replacement .
  27. Install the engine sight shield. Refer to Intake Manifold Sight Shield Replacement .
  28. Refill the fuel tank.
  29. Inspect for fuel leaks.
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