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Home >> Chevrolet >> 2012 >> Caprice 3.6 3 >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls/Fuel - 3.6L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Identifying Fuel Tank Strap To Chassis Retaining Bolts
    GM1949817Courtesy of GENERAL MOTORS COMPANY
  1. If the fuel tank was replaced, install the following components.
    2. NOTE:
    • Do not to damage the following components when installing the fuel tank assembly:
      • The fuel tank assembly wiring harness.
      • The fuel tank assembly electrical harness.
      • The fuel tank EVAP pipes.
    • Support the fuel tank assembly while installing the fuel tank assembly retaining straps to chassis retaining bolts (1).
  2. With the aid of an assistant install the fuel tank assembly to the vehicle.
  3. Install the fuel tank assembly retaining straps.
    4. CAUTION:

    Refer to Fastener Caution .

  4. Install the fuel tank assembly strap to chassis retaining bolts (1) and tighten to 30 N.m (22 lb ft).
    5. Fig 2: EVAP Emission Canister
    GM2661194Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Listen for an audible click to confirm correct installation of the EVAP emission hoses.

  5. Connect the EVAP emission hoses to the EVAP emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service .
    6. Fig 3: Supporting Rear Frame Assembly
    GM2172065Courtesy of GENERAL MOTORS COMPANY
  6. Raise and support the rear frame assembly (1) into its position using a suitable tool (2).
    7. Fig 4: Rear Frame Bolts
    GM2178933Courtesy of GENERAL MOTORS COMPANY
  7. Remove the EN-48536  tool (2) from the rear frame mounts (1).
    8. Fig 5: Rear Frame And Chassis Retaining Bolts
    GM2661187Courtesy of GENERAL MOTORS COMPANY
  8. Using a suitable tool clean the threaded holes (1 and 2) in the rear frame.
  9. Install NEW rear frame to chassis retaining bolts (2).

    Do not fully tighten at this stage.

  10. Install NEW rear frame to chassis retaining bolts (1).

    Do not fully tighten at this stage.

  11. Tighten the NEW rear frame to chassis retaining bolts (1) and (2).
    1. First Pass: Tighten the bolts to 65 N.m (48 lb ft).
    2. Final Pass: Tighten the bolts a further 125 degrees.
    12. Fig 6: Fuel Tank Electrical Connector
    GM2084586Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Listen for an audible click to confirm correct installation of the fuel tank electrical connector.

  12. Connect the fuel tank assembly electrical connector (1) to the chassis electrical harness.
    13. Fig 7: Identifying Fuel Feed Line & Fuel EVAP Hose
    GM1949815Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Listen for an audible click to confirm correct installation of the EVAP pipe (2) and the fuel feed pipe (1).

  13. Connect the EVAP pipe (2) to the EVAP chassis pipe.
  14. Connect the fuel feed pipe (1) to the chassis fuel feed pipe.
    15. Fig 8: EVAP Pipe And Fuel Tank Filler Vent Pipe
    GM2661049Courtesy of GENERAL MOTORS COMPANY
  15. Install the filler tube clamp (1) to the fuel tank assembly. Tighten the filler tube hose clamp (1) to 4 N.m (35 lb in).
    16. NOTE:

    Listen for an audible click to confirm correct installation of the EVAP hose (1).

  16. Install the EVAP pipe (1) to the fuel vent pipe.
  17. Connect the fuel feed line pressure sensor. Refer to Fuel Pressure Sensor Replacement - Fuel Feed Pipe .
  18. Install the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement .
  19. Install the parking brake rear cables. Refer to Parking Brake Rear Cable Replacement (9C3) , Parking Brake Rear Cable Replacement (9C1) .
  20. Install the propeller shaft. Refer to Propeller Shaft Replacement (Except 4L60) .
  21. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .
  22. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation .
  23. Lower the vehicle.
  24. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) , Battery Negative Cable Disconnection and Connection (Auxiliary) .
  25. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition, for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for leaks.
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