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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 >> Removal Procedure
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Removal Procedure

    Fig 1: Fuel Filler Pipe Jumper Hose
    GM889977Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Loosen the fuel filler pipe jumper hose clamp at the fuel tank (1).
  5. Disconnect the fuel filler pipe jumper hose from the fuel tank.
  6. Disconnect the vapor recirculation line that runs parallel to the fuel filler pipe jumper hose.
    7. Fig 2: Releasing Exhaust Pipe Insulators From Underbody Hangers
    GM1275979Courtesy of GENERAL MOTORS CORP.
  7. Release the exhaust pipe insulators from the underbody hangers.
  8. Release the muffler insulator from the underbody hanger and slowly lower the exhaust to rest on a tall jackstand. If this is not possible, remove the rear half of the exhaust system at the take down flange.
  9. Disconnect the fuel pump module harness electrical connector from the vehicle underbody wiring harness.
  10. Disconnect the evaporative emissions (EVAP) vent valve solenoid harness electrical connector from the vehicle underbody wiring harness.
  11. If applicable, disengage the antilock brake system (ABS) wiring harness from the retainer on the side of the EVAP canister.
    12. Fig 3: Capping Or Plugging Fuel Tank Feed And Vapor Return Pipes
    GM1236108Courtesy of GENERAL MOTORS CORP.
  12. Use an appropriate adjustable jack to support the fuel tank during removal.
  13. Remove the front left hand (LH) fuel tank strap bolts and strap.
  14. Remove the right hand (RH) tank strap bolts and strap.
  15. Using the adjustable jack, lower the fuel tank slightly in order to access the fuel line connections.
  16. Disconnect the fuel feed and purge lines at the fuel and brake line bundle on the right side of the vehicle.
  17. Cap or plug the fuel tank feed and vapor return pipes to prevent fuel loss and/or contamination.
  18. In order to clear the exhaust pipe, slowly lower the RH side of the fuel tank.
  19. Once the tank is clear of the RH frame rail, remove the fuel tank down and forward toward the RH side of the vehicle.
  20. If only the fuel tank is to be replaced, remove the fuel pump module assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
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