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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 >> Removal Procedure
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Removal Procedure

  1. Ignition OFF.
    2. WARNING: Refer to Battery Disconnect Warning in Cautions and Notices.
  2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
    3. WARNING: Refer to Gasoline/Gasoline Vapors Warning .
  3. Drain the fuel tank into a suitable container. Refer to Fuel Tank Draining .
    4. WARNING: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
    WARNING: Refer to Safety Glasses Warning .
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation .
  6. Remove the exhaust system for access. Refer to Exhaust System Replacement (V6 - For Access) or Exhaust System Replacement (V6 - Complete) .
  7. Remove the propeller shaft. Refer to Propeller Shaft Replacement .
  8. Remove the park brake cables. Refer to Parking Brake Rear Cable Replacement .
    9. Fig 1: Evap Line, Fuel Filler Hose & Clamps
    GM2193199Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the lower evaporative emission (EVAP) line (1) from the upper EVAP line (2). Refer to Plastic Collar Quick Connect Fitting Service .
  10. Remove the retaining hose clamp (3) from the fuel filler hose (4).
  11. Remove the retaining hose clamp (5) from the fuel filler hose (4).
  12. Remove the fuel filler hose (4) from the vehicle.
    13. Fig 2: Identifying Fuel Feed Line & Fuel EVAP Hose
    GM1949815Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the fuel feed line (1) using 7371 
  14. Disconnect the EVAP line (2). Refer to Plastic Collar Quick Connect Fitting Service .
    15. Fig 3: Fuel Tank Electrical Connector
    GM2084586Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the fuel tank electrical connector (1) from the chassis electrical harness.
    16. Fig 4: Supporting Rear Frame Assembly
    GM2172065Courtesy of GENERAL MOTORS CORP.
  16. Support the rear frame assembly (1) using a suitable tool (2).
    17. Fig 5: Identifying Rear Frame To Chassis Retaining Bolts
    GM1949819Courtesy of GENERAL MOTORS CORP.
  17. Remove the rear frame to chassis retaining bolts (1) and discard.
  18. Remove the rear frame to chassis retaining bolts (2) and discard.
    19. Fig 6: Rear Frame Bolts
    GM2178933Courtesy of GENERAL MOTORS CORP.
    NOTE: Make sure that the bolts (2) extends 50mm (2 in) from the rear frame.
  19. Install the bolts (2) of EN-48536  to the rear frame mounts (1).
    20. NOTE: When lowering the rear frame do not to damage the rear brake hoses.
  20. Lower the rear frame onto the bolts (2) of EN-48536  .
    21. Fig 7: EVAP Canister Vent Solenoid, Evap Canister Hose & Connectors
    GM2193200Courtesy of GENERAL MOTORS CORP.
  21. Detach the EVAP canister hose connector (2) from the EVAP canister (4). Refer to Plastic Collar Quick Connect Fitting Service .
    22. NOTE: Squeezes the collar of the EVAP canister hose connector (3) to release the connector.
  22. Detach the EVAP canister hose connector (3) from the EVAP canister (4).
  23. Disconnect the electrical connector (1) from the EVAP canister vent solenoid (5).
    24. Fig 8: Fuel Tank, Strap And Chassis Retaining Bolts
    GM2193196Courtesy of GENERAL MOTORS CORP.
    NOTE: Take care not to damage the following components when lowering the fuel tank assembly.
    • The fuel tank assembly wiring harness.
    • The fuel feed pipe.
    • The EVAP pipes.
    NOTE: Support the fuel tank assembly with a suitable tool before removing the fuel tank assembly straps to chassis retaining bolts (1)
  24. Remove the fuel tank strap to chassis retaining bolts (1).
  25. With the aid of an assistant, carefully manoeuvre the fuel tank assembly from the vehicle.
  26. Remove the following components if replacing the fuel tank:
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