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Home >> Pontiac >> 2005 >> Aztek Base, AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 3.4L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Identifying EVAP Canister & Purge Pipe
    GM670190Courtesy of GENERAL MOTORS CORP.
  1. Install the EVAP canister (3). Refer to Evaporative Emission (EVAP) Canister Replacement .
  2. Install the EVAP vent solenoid valve (2). Refer to Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement .
  3. Install the fuel sender assembly (1). Refer to Fuel Sender Assembly Replacement .
  4. Install the fuel and/or EVAP pipe assembly.
  5. Connect the EVAP vapor pipe to the fuel sender assembly.
  6. Connect the fuel feed and fuel return pipes at the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the fuel sender shield to the fuel tank.

    Tighten:  Tighten the shield nuts to 6 N.m (53 lb in).

  8. Connect the fuel tank wiring harness to the fuel sender assembly.
    9. Fig 2: Identifying Fuel Tank
    GM670194Courtesy of GENERAL MOTORS CORP.
  9. With the aid of an assistant, position and support the fuel tank.
    10. NOTE: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.
    Fig 3: Identifying Fuel Tank Strap Attaching Bolts
    GM670192Courtesy of GENERAL MOTORS CORP.
  10. Install the fuel tank retaining strap attaching bolts (2).

    Tighten:  Tighten the fuel tank retaining strap bolts to 47 N.m (35 lb ft).

    11. Fig 4: Locating EVAP Canister Bracket Retaining Nut
    GM669530Courtesy of GENERAL MOTORS CORP.
  11. Install the EVAP canister retaining nut.

    Tighten:  Tighten the EVAP canister retaining nut to 6 N.m (53 lb in).

    12. Fig 5: View Of Fuel Tank Filler Pipe Hose Clamp
    GM670051Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel tank filler pipe (2) to the fuel tank (1).

    Tighten:  Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).

    13. Fig 6: Identifying Quick-Connect Fitting On Fuel Filter
    GM670056Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel feed pipe quick-connect fitting (1) at the inlet side of the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  14. Connect the fuel return pipe quick-connect fitting near the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  15. Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.
    16. Fig 7: View Of Fuel Tank Wiring Harness Connector At Body Pass Through
    GM680801Courtesy of GENERAL MOTORS CORP.
  16. Connect the fuel tank wiring harness connector (1) at the body pass-through.
  17. Lower the vehicle.
  18. Add fuel and reinstall the fuel tank filler pipe cap.
  19. Connect the negative battery cable.
  20. Inspect for fuel leaks with the following procedure:
    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.
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