LEMON Manuals: Even more car manuals for everyone
Home >> Buick >> 2009 >> Lucerne CXL, 3.9 M >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 3.9L - Introduction >> Repair Instructions >> Fuel Tank Replacement (NU6) >> Installation Procedure

Installation Procedure

    Fig 1: View Of Fuel Pump Module O-Ring Seal
    GM1755314Courtesy of GENERAL MOTORS CORP.
  1. Place a NEW fuel pump module O-ring seal onto the fuel tank.
    2. NOTE: The bucket must be slightly tipped during installation to avoid bending the fuel level sensor float arm.
  2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
  3. Install the module lock ring, and move it into position on the top of the module.
  4. Lower the module assembly into the tank until the internal vent line quick connect fittings can be connected.
    5. Fig 2: Identifying Vent Line Quick Connect Fittings
    GM1755311Courtesy of GENERAL MOTORS CORP.
  5. Connect the internal vent line quick connect fittings to the module flange. Refer to Plastic Collar Quick Connect Fitting Service .
    6. Fig 3: View Of Wrench On Lock Ring
    GM1755307Courtesy of GENERAL MOTORS CORP.
  6. Install the J-45722:  wrench to the lock ring.
    7. Fig 4: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    NOTE: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.
    Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  7. Using the J-45722:  wrench and a breaker bar, rotate the fuel pump module lock ring clockwise until the ring is locked into place on the fuel tank.
  8. Remove the J-45722:  wrench.
    9. Fig 5: View Of Fuel Tank Electrical Harness Connector
    GM1755118Courtesy of GENERAL MOTORS CORP.
  9. Install the electrical harness.
  10. Connect the fuel tank electrical harness connector to the module.
  11. Install the electrical harness to the retaining features on the fuel tank.
    12. Fig 6: Identifying Fuel Tank Vent Line Quick Connect Fittings
    GM1755117Courtesy of GENERAL MOTORS CORP.
  12. Install the fuel tank vent lines.
  13. Connect the fuel tank vent line quick connect fittings to the module. Refer to Plastic Collar Quick Connect Fitting Service .
    14. Fig 7: Identifying Fuel Feed Line
    GM1755116Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel feed line.
  15. Connect the fuel feed line quick connect fitting to the module. Refer to Plastic Collar Quick Connect Fitting Service .
    16. Fig 8: Identifying Vent & Fuel Feed Lines
    GM1755115Courtesy of GENERAL MOTORS CORP.
  16. Install the retainer (3) to the vent and fuel feed lines.
  17. Install tape (1 and 2) to the fuel tank vent and fuel feed line in order to secure the lines.
    18. Fig 9: View Of Fuel Tank
    GM1671758Courtesy of GENERAL MOTORS CORP.
  18. Place the fuel tank onto the rear suspension crossmember.
    19. Fig 10: Identifying Adjustable Jack
    GM1671757Courtesy of GENERAL MOTORS CORP.
  19. Install the fuel tank straps.
    20. CAUTION: Refer to Fastener Caution .
  20. Install the fuel tank strap bolts and tighten to 46 N.m (34 lb ft).
  21. Install the rear coil springs while slowly raising the rear suspension crossmember using the adjustable jack (1).
    22. Fig 11: Locating Rear Suspension Crossmember Bolts
    GM1671755Courtesy of GENERAL MOTORS CORP.
  22. Install the rear suspension crossmember bolts and tighten to 191 N.m (141 lb ft).
  23. Remove the adjustable jack from the rear suspension crossmember.
  24. Remove the jack stand from the front of the vehicle.
    25. Fig 12: Identifying Rear Shock Bolts
    GM1671754Courtesy of GENERAL MOTORS CORP.
  25. Install the rear shock bolts and tighten to 25 N.m (18 lb ft).
    26. Fig 13: View Of Fuel Tank Harness Electrical Connector & Clips
    GM1671752Courtesy of GENERAL MOTORS CORP.
  26. Connect the body harness electrical connector to the fuel tank harness electrical connector (1).
  27. Install the fuel tank harness clips (2, 3) to the rear compartment side rail.
    28. Fig 14: Identifying Fuel & EVAP Line Retainer
    GM1671751Courtesy of GENERAL MOTORS CORP.
  28. Install the fuel and EVAP line retainer (1) to the side rail.
    29. Fig 15: Identifying Fuel Tank Wiring Harness Electrical Connector
    GM1755107Courtesy of GENERAL MOTORS CORP.
  29. Connect the fuel tank wiring harness electrical connector (2) to the fuel tank pressure sensor.
    30. Fig 16: Identifying Chassis Line Quick Connect Fitting
    GM1671750Courtesy of GENERAL MOTORS CORP.
  30. Connect the fuel feed line quick connect fitting (1) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
    31. Fig 17: Identifying Fuel Fill Pipe Vent Line & Fuel Tank Vapor Line Quick Connect Fittings
    GM1671749Courtesy of GENERAL MOTORS CORP.
  31. Connect the fill pipe vent line (2) and the fuel tank vapor line (3) quick connect fittings to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
    32. Fig 18: View Of Rear Brake Hose Bracket
    GM1671753Courtesy of GENERAL MOTORS CORP.
  32. Install the left and right rear brake hose bracket studs into the keyhole slots. Tighten the nuts to 10 N.m (89 lb in).
  33. Install the exhaust system. Refer to Exhaust System Replacement .
    34. Fig 19: Identifying Electronic Suspension Front Position Sensor Link
    GM1665080Courtesy of GENERAL MOTORS CORP.
  34. Connect the left and right electronic position sensor links (1) to the ball studs.
    35. Fig 20: Identifying Fuel Tank EVAP Recirculation Line Quick Connect Fitting
    GM1671747Courtesy of GENERAL MOTORS CORP.
    NOTE: Clean the fill pipe or any dirt or debris. Ensure the fill pipe is installed to the original depth to the fill hose. The fill pipe bead must be inserted into the hose past the clamp position.
  35. Connect the fuel tank EVAP recirculation line quick connect fitting (1) to the fill pipe line. Refer to Plastic Collar Quick Connect Fitting Service .
  36. Connect the fuel fill hose (2) to the fuel fill pipe.
    37. Fig 21: Identifying Fuel Fill Hose Clamp
    GM1671746Courtesy of GENERAL MOTORS CORP.
  37. Tighten the fuel fill hose clamp (1) at the fill pipe. Tighten the clamp to 4 N.m (35 lb in).
  38. Install the left rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement .
  39. Fill the fuel tank.
  40. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  41. Perform the following procedure in order to inspect for leaks:
    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.
scientia non olet · About LEMON Manuals