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Home >> Pontiac >> 2009 >> G8 Base >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System & Fuel System - 3.6L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

  1. If the fuel tank was replaced, install the following components:
    2. Fig 1: Fuel Tank, Strap And Chassis Retaining Bolts
    GM2193196Courtesy of GENERAL MOTORS CORP.
    NOTE: Take care not to damage the following components when installing the fuel tank assembly to the vehicle:
    • The fuel tank assembly wiring harness.
    • The fuel feed pipe.
    • The Evap pipes.
    NOTE: Support the fuel tank assembly with a suitable tool while installing the fuel tank assembly straps to chassis retaining bolts (1).
  2. With the aid of an assistant, carefully manoeuvre and install the fuel tank assembly to the vehicle.
    3. CAUTION: Refer to Fastener Caution in Cautions and Notices.
  3. Install the fuel tank assembly strap to chassis retaining bolts (1) and tighten to 20 N.m (15 lb ft).
    4. Fig 2: EVAP Canister Vent Solenoid, Evap Canister Hose & Connectors
    GM2193200Courtesy of GENERAL MOTORS CORP.
    NOTE: Listen for an audible click to confirm correct installation.
  4. Connect the electrical connector (1) to the EVAP emission canister vent solenoid (5).
  5. Attach the EVAP canister hose connector (2) to the EVAP canister (4). Refer to Plastic Collar Quick Connect Fitting Service .
  6. Attach the EVAP canister hose connector (3) to the EVAP canister (4).
    7. Fig 3: Supporting Rear Frame Assembly
    GM2172065Courtesy of GENERAL MOTORS CORP.
  7. Raise and support the rear frame assembly (1) into its position using a suitable tool (2).
    8. Fig 4: Rear Frame Bolts
    GM2178933Courtesy of GENERAL MOTORS CORP.
  8. Remove the bolts (2) of EN-48536  from the rear frame mounts (1).
    9. Fig 5: Identifying Rear Frame To Chassis Retaining Bolts
    GM1949819Courtesy of GENERAL MOTORS CORP.
    NOTE: Using a suitable tool clean the threaded holes of the rear frame to chassis retaining bolts.
  9. Install the NEW rear frame to chassis retaining bolts (2).

    Do not fully tighten at this stage.

  10. Install the NEW rear frame to chassis retaining bolts (1).

    Do not fully tighten at this stage.

  11. Tighten the NEW rear frame to chassis retaining bolts (1) and (2) to:

    First Pass:  Tighten the bolts to 65 N.m (48 lb ft).

    Final Pass:  Tighten the bolts a further 125 degrees.

    12. Fig 6: Fuel Tank Electrical Connector
    GM2084586Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel tank assembly electrical connector (1) to the chassis electrical harness.
    13. Fig 7: Identifying Fuel Feed Line & Fuel EVAP Hose
    GM1949815Courtesy of GENERAL MOTORS CORP.
    NOTE: Listen for an audible click to confirm correct installation.
  13. Connect the EVAP line (2) to the EVAP chassis pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the fuel feed line (1) to the chassis fuel feed pipe.
    15. Fig 8: Evap Line, Fuel Filler Hose & Clamps
    GM2193199Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel filler hose (4) to the vehicle.
  16. Install the retaining hose clamp (3) to the fuel filler hose (4) and tighten to 4 N.m (35 lb in).
  17. Install the retaining hose clamp (5) to the fuel filler hose (4) and tighten to 4 N.m (35 lb in).
  18. Connect the lower EVAP line (1) to the upper EVAP line (2). Refer to Plastic Collar Quick Connect Fitting Service .
  19. Install the park brake cables. Refer to Parking Brake Rear Cable Replacement .
  20. Install the propeller shaft. Refer to Propeller Shaft Replacement .
  21. Install the exhaust system. Refer to Exhaust System Replacement (V6 - For Access) or Exhaust System Replacement (V6 - Complete) .
  22. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation .
  23. Lower the vehicle to the ground.
  24. Fill the fuel tank with the drained fuel.
  25. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  26. Inspect for fuel leaks using the following procedure:
    • Turn ON the ignition, with the engine OFF for 2 seconds.
    • Turn OFF the ignition, for 10 seconds.
    • Turn ON the ignition, with the engine OFF.
    • Inspect for leaks.
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