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Home >> Pontiac >> 2005 >> Sunfire Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 2.2L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Identifying Fuel Tank
    GM49897Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel pump module assembly to the fuel tank. Refer to Fuel Pump Module Replacement .
  2. With the aid of an assistant, raise the fuel tank (1) to the vehicle.
    3. NOTE: Refer to Fastener Notice .
  3. Install the fuel tank retaining straps.

    Tighten:  Tighten the strap bolts to 35 N.m (26 lb ft).

  4. Connect the wiring harness into the multi-way rear body connector.
  5. Connect the EVAP vapor pipe to the EVAP canister.
  6. Connect the fuel filler hose to the fuel tank.

    Tighten:  Tighten the fuel filler hose clamp to 3 N.m (27 lb in).

  7. Install the rubber exhaust hangers.
  8. Install the exhaust heat shield.

    Tighten: 

    • Tighten the exhaust shield bolt to 2 N.m (18 lb in).
    • Tighten the exhaust shield nuts to 1 N.m (9 lb in).

  9. Connect the fuel return pipe and fuel filter quick-connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  10. Lower the vehicle.
  11. Refill the fuel tank.
  12. Install the fuel filler cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  14. 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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