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Home >> Pontiac >> 2004 >> GTO Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls -- 5.7L -- (Introduction) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

  1. Lift and install the fuel tank (2) into the lower plastic fuel tank shell.
    Fig 1: View Of Fuel Tank Plastic Shells & Fuel Tank
    GM1372272Courtesy of GENERAL MOTORS CORP.
  2. Install the upper plastic fuel tank shell.
  3. Clip the fuel tank to body wiring harness electrical connector mounting clip, onto the lower plastic fuel tank shell.
    4. Fig 2: Locating Santoprene Hose & Fuel Tank Vapor Recirculation Line
    GM1372271Courtesy of GENERAL MOTORS CORP.
  4. Install the santoprene hose (3) on and around the filler neck flange moulding and down along the fuel filler neck.
  5. Reconnect the fuel tank vapor recirculation line (1) quick connect fitting. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  6. Install the santoprene hose (3) on and around the fuel tank cover flange.
    7. Fig 3: View Of Fill Pipe
    GM1372270Courtesy of GENERAL MOTORS CORP.
  7. Install new hose clamps (1 and 3) to the fill pipe (2).
  8. With the assistance of another person, install the fuel tank and filler neck assembly to the vehicle.
    9. Fig 4: View Of Fuel Tank & Mounting Straps
    GM1372269Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install each of the mounting straps (3), and fasten with the 2 fuel tank upper mounting strap nuts (1).

    Tighten:  Tighten the fuel tank mounting strap upper fastening nut to 20 N.m (15 lb ft).

  10. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    11. Fig 5: Locating Lower Fuel Tank Mounting Strap Nuts
    GM1372268Courtesy of GENERAL MOTORS CORP.
  11. Install the lower fuel tank mounting strap nuts (1).

    Tighten:  Tighten the fuel tank mounting strap lower fastening nut to 40 N.m (30 lb ft).

    12. Fig 6: View Of Fuel Feed Line & Fuel Tank Vent Line Quick Connect Fittings
    GM1372267Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel feed line quick connect fitting (1).
  13. Connect the fuel tank to fuel feed line quick connect fitting (2). Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  14. Install the fuel tank vent line quick connect fitting (2). Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  15. Lower the vehicle.
    16. Fig 7: View Of Fuel Filler Door, Cap & Pocket
    GM1372266Courtesy of GENERAL MOTORS CORP.
  16. Install the 3 nuts (1) securing the fuel filler neck to the filler pocket (4).

    Tighten:  Tighten the fuel filler neck to filler pocket fastening nut to 5 N.m (44 lb in).

  17. Install the fuel filler cap (3).
    18. Fig 8: View Of Fuel Tank Harness Electrical Connector
    GM1372264Courtesy of GENERAL MOTORS CORP.
  18. Connect the body wiring harness to fuel tank harness electrical connector (1).
  19. Install the rear compartment support brace to gain access to the fuel tank. Refer to Support Brace Replacement - Rear Compartment in Body Rear End.
  20. Refill the fuel tank and check for leaks.
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