Fuel Tank: Installation

With aid of an assistant, position fuel tank with heat shield and straps under vehicle.

Fig 1: Reinstalling Fuel Tank
Courtesy of GENERAL MOTORS CORP.
Attach electrical connectors to fuel pump and tank pressure sensor.
Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts to underbody.
Torque:

Fuel Tank Mounting Strap: 20 N.m (15 ft-lbs)

NOTE: Replace plastic fuel line retainers whenever fuel supply lines are disconnected. Install new retainer into female portion of connection. Care must be taken to ensure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
Install new retainers into female portion of quick-connect fittings on underbody fuel and EVAP canister purge lines.
NOTE: Replace plastic fuel line retainers whenever fuel supply lines are disconnected at fuel filter and fuel rail. Install new retainer into female portion of connection. Care must be taken to assure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.

IMPORTANT: Lubricate male ends of filter with clean engine oil to ease installation.
Connect fuel feed return and vapor lines.
Install fuel tank grounding attachment nut located near the fuel filter.
Torque:

Fuel Tank Grounding Attachment

Nut: 4.5 N.m (40 in-lbs)

IMPORTANT: Ensure that EVAP vent solenoid pipe is installed in position on filler pipe bracket.

Fig 2: Installing Vent Solenoid Pipe To Filler Pipe Bracket
Courtesy of GENERAL MOTORS CORP.
Loosely install filler pipe lower bracket attachment screw but do not tighten.
Install fill neck to fuel tank.
NOTE: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6mm (1/4 in.) of the end of the connector hose.
Tighten hose clamp on filler pipe to fuel tank connecting hose.
Torque:

Fuel Fill Neck-to-Fuel Tank Clamp: 5 N.m (44 in-lbs)

Fig 3: Connecting Fuel Tank To Connecting Hose
Courtesy of GENERAL MOTORS CORP.
Connect EVAP canister vent pipe at quick connect to canister vent hose.

Fig 4: Connecting EVAP Canister Vent Pipe
Courtesy of GENERAL MOTORS CORP.
Tighten lower attachment screw on filler pipe to underbody.
Torque:

Fuel Fill Pipe-to-Body (Lower): 13 N.m (115 in-lbs)
Install heat shield.
Torque:

Rear Heat Shield: 8 N.m (69 in-lbs)
Install fuel tank strap bracket (fuel line stone chip guard).
Torque:

Fuel Tank Stone Guard-to-Body: 10 N.m (89 in-lbs)

Fig 5: Reinstalling Fuel Line Stone Chip Guard
Courtesy of GENERAL MOTORS CORP.
Install intermediate pipe (with muffler).
Add fuel and connect negative battery cable.
Torque:

Battery Terminal Bolts: 17 N.m (13 ft-lbs)
Prime fuel system.
1. Cycle ignition On for 5 seconds and then Off for 10 seconds.
2. Repeat previous step twice.
3. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
4. If engine does not start, repeat steps 1 - 3 .
Fig 6: Reconnecting Intermediate Pipe To Muffler
Courtesy of GENERAL MOTORS CORP.