LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Pontiac >> 2005 >> Grand Prix Base >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 3.8L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removal Procedure

IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system fuel 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. Fig 1: View Of Fuel Tank Fill Hose
    GM1554559Courtesy of GENERAL MOTORS CORP.
  4. Loosen the fuel fill hose clamp (1) at the fuel tank.
  5. Remove the fuel tank fill hose (2) from the fuel tank (3).
    6. Fig 2: View Of EVAP Vent Valve Solenoid Hose
    GM1554566Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the EVAP vent solenoid hose (2) on the tank from the EVAP vent valve solenoid hose (1).
    7. Fig 3: View Of Fill Pipe EVAP Vent Pipe Quick Connect Fitting
    GM1554568Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the EVAP vent pipe quick connect fitting (4) from the fill pipe EVAP vent pipe quick connect fitting (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    8. Fig 4: View Of Fuel Feed, EVAP and Fuel Tank Lines
    GM1554561Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the fuel feed (3), and the EVAP (4) lines from the fuel tank lines (1, 2). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  9. Support the exhaust system.
  10. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
    11. Fig 5: View Of Fuel Tank Shield
    GM1554563Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel tank shield retainers (3).
  12. Remove the fuel tank shield (2).
    13. Fig 6: View Of Fuel Tank & Straps
    GM1554562Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not bend the fuel tank straps as this may damage the straps.
  13. Support the fuel tank with a suitable adjustable jack.
  14. Remove the fuel tank strap bolts (3).
  15. Using the jack lower the fuel tank.
    16. Fig 7: View Of Fuel Sender Jumper Harness Electrical Connector
    GM1575953Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the fuel sender jumper harness electrical connector.
  17. Remove the fuel tank and place the tank in a suitable work area.
    18. Fig 8: View Of Top Of Fuel Tank
    GM1575955Courtesy of GENERAL MOTORS CORP.
  18. Disconnect and remove the fuel pressure sensor and fuel sender jumper harness electrical connectors.
    19. Fig 9: View Fuel Tank Lines
    GM1575957Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Note the routing of the lines for installation.
  19. Disconnect and remove the fuel feed line (3), and the EVAP lines (1, 2). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  20. Remove the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  21. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.
scientia non olet · About LEMON Manuals