Fuel Tank: Installation

With aid of an assistant, position fuel tank under vehicle.
Attach electrical connectors to fuel pump and tank pressure sensor.

Fig 1: Installing Fuel Tank
Courtesy of GENERAL MOTORS CORP.

NOTE: Position the fuel tank solidly against the left hand underbody side rail prior to tightening the strap mounting bolts. A small white locator button on the left side of the fuel tank shell should be tight against the left side rail at the completion of installation.
Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts (15 mm hex) to underbody.
Torque:

Fuel Tank Straps-to-Body: 47 N.m (35 ft-lbs)
Install (2) mounting screws (10 mm hex) for the fuel filter/pressure regulator bracket.

Fig 2: Fuel Filter/Pressure Regulator Bracket
Courtesy of GENERAL MOTORS CORP.

Torque:

Fuel Filter/Pressure Regulator-to-Frame

Rail: 8 N.m (71 in-lbs)

NOTE: Replace the plastic fuel line retainers whenever the fuel supply lines are disconnected at the fuel filter/pressure regulator and fuel rail. Install the new retainer into the female portion of the connection. Care must be taken to assure that the locking tab is centered in the window of the female connection. Firmly press the male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
Install a new retainer into the female portion of the of the 90° quick-connect fitting on the underbody fuel feed line.
NOTE: Lubricate the male ends of the filter/regulator with clean engine oil to ease installation.
Install the underbody fuel feed line onto the outlet of filter/regulator.

Fig 3: Underbody Fuel Feed Line
Courtesy of GENERAL MOTORS CORP.
Insure that fuel filler check valve is in place at the end of fuel filler pipe.
NOTE: To ease installation, lightly wipe the outside of the fuel tank inlet connector with plain water.
Position filler pipe into wheel opening with top of pipe within body panel opening.
Install fuel filler pipe into fuel tank opening.
Loosely install filler pipe lower bracket attachment screw (10 mm hex) but do not tighten.
NOTE: Insure that EVAP vent solenoid pipe is installed in position on filler pipe bracket.
Lower vehicle and install filler pipe upper bracket attachment screw (T-30).
Torque:

Fuel Tank Fill Pipe-to-Upper

Bracket: 4 +/- .5 N.m (35 +/- 4 in-lbs)

Fig 4: Installing Filler Pipe
Courtesy of GENERAL MOTORS CORP.
Install rubber closeout grommet to body and filler pipe.
Install fuel cap.
Raise vehicle to comfortable working height.
NOTE: Ensure that the fuel pipe connecting hose is installed to within 6 mm (1/4 in.) of the stops on the fuel tank inlet connector. The hose clamp should be located within 4 mm (3/16 in.) of the end of the connecting hose.
Tighten hose clamp (7 mm hex) on filler pipe to fuel tank connecting hose.
Torque:

Fuel Tank Fill Hose-to-Clamp: 4 +/- .5 N.m (35 +/- 4 in-lbs)
Connect EVAP canister vent pipe at quick connect to canister vent hose.

Fig 5: Connecting EVAP Canister Vent Pipe
Courtesy of GENERAL MOTORS CORP.
Tighten lower attachment screw on filler pipe to underbody.
Torque:

Fuel Tank Fill Pipe-to-Underbody Rail: 8 N.m (71 in-lbs)
Connect wiring harness to EVAP vent solenoid.
Install wheelhouse inner liner to wheel opening.
Add fuel, install filler cap, and connect negative battery cable.
Torque:

Battery Terminal Bolts: 17 N.m (13 ft-lbs)
Prime fuel system using either of the following methods:
- Using ignition, cycle switch On for five seconds and then Off for 10 seconds. Repeat this twice.
- Energize the fuel pump using the Scan tool. Refer to ENERGIZING THE FUEL PUMP . Run the pump for 10-20 seconds.
Examine fuel supply line for leaks at filter/pressure regulator.
Crank engine until it starts (allowing a maximum of 15 seconds of cranking time).
Perform the "Service Bay Diagnostic Test" for the evaporative emission system using the Scan tool. This test will verify the integrity of the vapor handling areas of the fuel system.