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Home >> Pontiac >> 2005 >> G6 Base >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 3.5L (Lx9) - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Capping Or Plugging Fuel Tank Feed And Vapor Return Pipes
    GM1236108Courtesy of GENERAL MOTORS CORP.
  1. If fuel tank replacement was necessary, install the fuel pump module assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  2. Begin to install the LH side of the fuel tank over the exhaust pipe.
  3. Raise the RH side of the fuel tank into position inboard of the RH frame rail. Use care in feeding the fuel feed, the EVAP vapor pipe, and the fuel pump module electrical harness over the exhaust system.
  4. Remove the caps or plugs from the fuel tank feed and vapor return pipes.
  5. Connect the fuel feed and vapor purge lines to the fuel and brake line bundle on the right side of the vehicle.
  6. Fully raise and install the fuel tank into position.
  7. Install the RH fuel tank strap and strap bolts.
  8. Install the LH fuel tank strap and strap bolts.
    9. NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Tighten the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

  10. Remove the adjustable jack from under the fuel tank.
  11. If applicable, engage the ABS wiring harness to the retainer on the side of the EVAP canister.
  12. Connect the EVAP vent valve solenoid harness electrical connector to the vehicle underbody wiring harness.
    13. Fig 2: Releasing Exhaust Pipe Insulators From Underbody Hangers
    GM1275979Courtesy of GENERAL MOTORS CORP.
  13. Raise the exhaust into position and install the muffler insulator to the underbody hanger.
  14. Install the exhaust extension pipe insulators to the underbody hangers.
  15. Connect the fuel pump module harness electrical connector to the vehicle underbody connector.
    16. Fig 3: Fuel Filler Pipe Jumper Hose
    GM889977Courtesy of GENERAL MOTORS CORP.
  16. Connect the fuel filler pipe jumper hose to the fuel tank.
  17. Tighten the fuel filler pipe jumper hose clamp (1) at the fuel tank.

    Tighten:  Tighten the clamp to 4 N.m (35 lb in).

  18. Connect vapor recirculation line that runs parallel to the fuel filler pipe jumper hose.
  19. Lower the vehicle.
  20. Refill the fuel tank.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  22. 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 fuel leaks.
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