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Home >> Pontiac >> 2005 >> Grand Prix Base >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 3.8L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

NOTE:
  • Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle.
  • Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes.
  • Replace the vapor pipes with original equipment or parts that meet GM specifications.
  • Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the hose.
    Fig 1: View Fuel Tank Lines
    GM1575957Courtesy of GENERAL MOTORS CORP.
  1. Install the insulator pads to the fuel tank.
  2. Install the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  3. Install and connect the fuel feed line (3), and the EVAP lines (1, 2). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    4. Fig 2: View Of Top Of Fuel Tank
    GM1575955Courtesy of GENERAL MOTORS CORP.
  4. Install and connect the fuel pressure sensor and fuel sender jumper harness electrical connectors.
  5. Install the fuel tank onto a suitable jack.
  6. Partially raise the fuel tank until the electrical connections can be made.
    7. Fig 3: View Of Fuel Sender Jumper Harness Electrical Connector
    GM1575953Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel sender jumper harness electrical connector.
    8. Fig 4: View Of Fuel Tank & Straps
    GM1554562Courtesy of GENERAL MOTORS CORP.
  8. Completely raise the tank.
    9. NOTE: Refer to Fastener Notice in Cautions and Notices.
  9. Install the fuel tank strap bolts (3).

    Tighten:  Tighten the bolts to 48 N.m (35 lb ft).

  10. Remove the jack from the fuel tank.
    11. Fig 5: View Of Fuel Tank Shield
    GM1554563Courtesy of GENERAL MOTORS CORP.
  11. Position the fuel tank shield (2) to the fuel tank.
  12. Install the shield retainers (3).
    13. Fig 6: View Of Fuel Feed, EVAP and Fuel Tank Lines
    GM1554561Courtesy of GENERAL MOTORS CORP.
  13. Install the rubber exhaust pipe hangers.
  14. Remove the support from the exhaust system.
  15. Connect the fuel feed (3), and EVAP (4) lines to the fuel tank lines (1, 2). Refer to Quick Connect Fitting(s) Service (Plastic Collar)
    16. Fig 7: View Of Fill Pipe EVAP Vent Pipe Quick Connect Fitting
    GM1554568Courtesy of GENERAL MOTORS CORP.
  16. Connect the EVAP vent pipe quick connect fitting (4) to the fill pipe EVAP vent pipe quick connect fitting (1). Quick Connect Fitting(s) Service (Plastic Collar) .
    17. Fig 8: View Of EVAP Vent Valve Solenoid Hose
    GM1554566Courtesy of GENERAL MOTORS CORP.
  17. Connect the EVAP vent solenoid hose (2) on the tank to the EVAP vent valve solenoid hose (1).
    18. Fig 9: View Of Fuel Tank Fill Hose
    GM1554559Courtesy of GENERAL MOTORS CORP.
  18. Install the fuel tank fill hose (2) onto the fuel tank (3). Install the hose over the orientation feature (4) on the tank until fully seated to the tank.
  19. Tighten the fuel fill hose clamp (1) at the fuel tank.

    Tighten:  Tighten the clamp to 2.5 N.m (22 lb in).

  20. Lower the vehicle.
  21. Add fuel and install the fuel fill cap.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (RPOs L26/L32) or Battery Negative Cable Disconnect/Connect Procedure (RPO LS4) .
  23. Inspect the fuel system for leaks by performing the following steps:
    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.
  24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26) or Fuel Injector Sight Shield Replacement (L32) .
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