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

  1. Siphon as much fuel as possible from the fuel tank, refer to Fuel Tank Draining Procedure .
  2. Remove the rear compartment support brace to gain access to the fuel tank.Support Brace Replacement - Rear Compartment in Body Rear End.
    3. Fig 1: View Of Fuel Tank Harness Electrical Connector
    GM1372264Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the body wiring harness to fuel tank harness electrical connector (1).
    4. Fig 2: View Of Fuel Filler Door, Cap & Pocket
    GM1372266Courtesy of GENERAL MOTORS CORP.
  4. From behind the fuel filler door (2) unscrew the fuel filler cap (3) and cover the end of the fuel filler neck with a suitable material to prevent foreign objects from entering.
  5. Remove the 3 nuts (1) securing the fuel filler neck to the filler pocket (4).
  6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    7. Fig 3: View Of Fuel Feed Line & Fuel Tank Vent Line Quick Connect Fittings
    GM1372267Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel feed line quick connect fitting (1), refer to Quick Connect Fitting(s) Service (Metal Collar) .
  8. Disconnect the fuel tank to fuel feed line quick connect fitting (2). Refer to Quick Connect Fitting(s) Service (Metal Collar) , and place the feed line to one side.
  9. Remove the fuel tank vent line quick connect fitting (2). Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    10. Fig 4: Locating Lower Fuel Tank Mounting Strap Nuts
    GM1372268Courtesy of GENERAL MOTORS CORP.
  10. Remove the lower fuel tank mounting strap nuts (1).
    11. Fig 5: View Of Fuel Tank & Mounting Straps
    GM1372269Courtesy of GENERAL MOTORS CORP.
  11. Lower the vehicle and from within the rear compartment, remove the 2 fuel tank upper mounting strap nuts (1) and remove each of the mounting straps (3).
  12. If installed, cut and dispose of the shipping strap.
    IMPORTANT: The shipping strap is used for fuel tank shipping purposes only and does not require reinstallation.
  13. With the assistance of another person, remove the fuel tank and filler neck assembly from the vehicle.
    14. Fig 6: View Of Fill Pipe
    GM1372270Courtesy of GENERAL MOTORS CORP.
  14. Remove and discard the hose clamps (1 and 3) from the fill pipe (2).
    15. Fig 7: Locating Santoprene Hose & Fuel Tank Vapor Recirculation Line
    GM1372271Courtesy of GENERAL MOTORS CORP.
  15. Remove the santoprene hose (3) off from around the filler neck flange moulding and down along the fuel filler neck.
  16. Disconnect the fuel tank vapor recirculation line (1) quick connect fitting. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  17. Remove the santoprene hose (3) off from around the fuel tank cover flange.
  18. Unclip the fuel tank to body wiring harness electrical connector from its mounting clip which connects onto the lower plastic fuel tank shell.
    19. Fig 8: View Of Fuel Tank Plastic Shells & Fuel Tank
    GM1372272Courtesy of GENERAL MOTORS CORP.
  19. Wedge a large flat blade screwdriver in between the side skirting of each of the upper and lower plastic fuel tank shells (1 and 3), and pull each of the 8 clipping points free to separate and remove the upper plastic fuel tank shell as indicated.
  20. Lift and remove the fuel tank (2) from the lower plastic fuel tank shell.
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