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Home >> Chevrolet >> 2004 >> Monte Carlo LS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System 3.4L (Introduction) >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
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Removal Procedure

    NOTE: Refer to Cover and Plug Openings Notice in Cautions and Notices.
    IMPORTANT: Always maintain cleanliness when servicing the fuel system components.
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Loosen the fuel filler hose clamp (1) at the fuel tank (3).
    5. Fig 1: Identifying Fuel Tank Components
    GM186674Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel tank filler hose from the fuel tank.
    6. Fig 2: Fuel Tank Filler Hose
    GM155468Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel feed, the fuel return and the evaporative emission (EVAP) pipes quick-connect fittings at the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. Fig 3: Removing Quick-Connect Fittings
    GM32401Courtesy of GENERAL MOTORS CORP.
  7. Remove the exhaust pipe hangers in order to allow the exhaust system to drop slightly.
  8. Separate the 2 halves of the EVAP fresh air hose at the splice.
    9. Fig 4: Separating 2 Halves Of EVAP Fresh Air Hose
    GM698635Courtesy of GENERAL MOTORS CORP.
  9. Remove the fuel tank shield push pins (2) and the fuel tank shield (3).
    10. Fig 5: Removing Fuel Tank Shield
    GM699555Courtesy of GENERAL MOTORS CORP.
  10. Support the fuel tank with a suitable jack.
    11. NOTE: Do not bend the fuel tank straps as this may damage the straps.
  11. Remove the fuel tank strap bolts (2).
  12. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
    13. Fig 6: Removing Fuel Tank
    GM699556Courtesy of GENERAL MOTORS CORP.
  13. Remove the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  14. Remove the fuel feed, the fuel return, and the EVAP pipe assemblies and the insulator clips from the fuel tank.
  15. Remove the insulator pad from the fuel tank. Note the location of the insulator pad for the installation.
    16. Fig 7: View OF Fuel Tank & EVAP Canister
    GM531026Courtesy of GENERAL MOTORS CORP.
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