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Home >> Chevrolet >> 2011 >> Impala LTZ >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 3.9L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: View Of Fuel Tank Lines
    GM1575957Courtesy of GENERAL MOTORS CORP.
  1. Install the insulator pads to the fuel tank.
  2. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .
    3. CAUTION:
    • Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle.
    • Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes.
    • Replace the vapor pipes with original equipment or parts that meet GM specifications.
    • Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the hose.
  3. Install and connect the fuel feed line (2), and the EVAP lines (1, 3). Refer to Plastic Collar Quick Connect Fitting Service .
    4. Fig 2: View Of Top Of Fuel Tank
    GM1575955Courtesy of GENERAL MOTORS CORP.
  4. Install and connect the fuel pressure sensor and fuel sender jumper harness electrical connectors.
  5. Install the fuel tank onto a suitable jack.
  6. Partially raise the fuel tank until the electrical connection can be made.
    7. Fig 3: View Of Fuel Sender Jumper Harness Electrical Connector
    GM1575953Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel sender jumper harness electrical connector.
    8. Fig 4: View Of Fuel Tank & Straps
    GM1554562Courtesy of GENERAL MOTORS CORP.
  8. Completely raise the tank.
    9. CAUTION: Refer to Fastener Caution .
  9. Install the fuel tank strap bolts (3).

    Tighten:  Tighten the bolts to 48 N.m (35 lb ft).

  10. Remove the jack from the fuel tank.
    11. Fig 5: View Of Fuel Tank Shield
    GM1554563Courtesy of GENERAL MOTORS CORP.
  11. Position the fuel tank shield (2) to the fuel tank.
  12. Install the shield retainers (3).
    13. Fig 6: View Of Fuel Feed, EVAP and Fuel Tank Lines
    GM1554561Courtesy of GENERAL MOTORS CORP.
  13. Install the rubber exhaust pipe hangers.
  14. Remove the support from the exhaust system.
  15. Connect the fuel feed (3), and EVAP (4) lines to the fuel tank lines (1, 2). Refer to Plastic Collar Quick Connect Fitting Service .
    16. Fig 7: EVAP Canister Vent Solenoid Valve And EVAP Emission Canister Hose
    GM1618911Courtesy of GENERAL MOTORS CORP.
  16. Connect the EVAP vent solenoid hose on the tank to the EVAP vent valve solenoid hose.
    17. Fig 8: Fuel Tank Clamp, Fuel Tank Hose and Fuel Tank
    GM1554559Courtesy of GENERAL MOTORS CORP.
  17. Connect the EVAP vent pipe quick connect fitting to the fill pipe EVAP vent pipe quick connect fitting. Plastic Collar Quick Connect Fitting Service .
  18. Install the fuel tank fill hose (2) onto the fuel tank (3). Install the hose over the orientation feature (4) on the tank until fully seated to the tank.
  19. Tighten the fuel fill hose clamp (1) at the fuel tank.

    Tighten:  Tighten the clamp to 2.5 N.m (22 lb in).

  20. Lower the vehicle.
  21. Add fuel and install the fuel fill cap.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LGD/LZE) .
  23. Inspect the fuel system for leaks by performing the following steps:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
  24. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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