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Home >> Chevrolet >> 2016 >> Volt Premier >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 1.5L (L3A) - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

    Fig 1: Fuel Tank And Suitable Jack
    GM4091017Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    A second technician is required.

  1. Raise the fuel tank (1) slowly using the suitable adjustable jack (3).
  2. Move the fuel tank (1) forwards.
    3. Fig 2: Fuel Tank Straps
    GM4091016Courtesy of GENERAL MOTORS COMPANY
  3. Install Fuel Tank Straps (1) (Qty: 2)
    4. CAUTION:

    Refer to Fastener Caution

  4. Install the 4 fuel tank strap bolts (2, 4) and tighten to 22 N.m (16 lb ft).
  5. Remove the suitable jack (3) from the fuel tank.
  6. Return the rear axle to its original position.
  7. Support the rear axle with a suitable jack stand.
    8. Fig 3: Right Side Rear Axle Bracket Bolts And Washers
    GM4064443Courtesy of GENERAL MOTORS COMPANY
  8. Install Washers (2) (Qty: 3)
    9. WARNING:

    Refer to Torque-to-Yield Fastener Warning .

    CAUTION:

    Refer to Fastener Caution

  9. Install 3 NEW right side axle bracket bolts (1). Refer to Rear Axle Bracket Replacement
    10. Fig 4: Left Side Rear Axle Bracket Bolts And Washers
    GM4551104Courtesy of GENERAL MOTORS COMPANY
  10. Install Washers (2) (Qty: 3)
  11. Remove and DISCARD the left side axle bracket bolts. Install 3 NEW left side axle bracket bolts (1). Refer to Rear Axle Bracket Replacement
    12. Fig 5: Shock And Lower Shock Fasteners
    GM4217522Courtesy of GENERAL MOTORS COMPANY
  12. Support the rear axle and remove and DISCARD the lower shock bolt (2).
  13. Install the rear coil springs. Refer to Rear Coil Spring Replacement .
    14. Fig 6: Fuel Feed Pipe
    GM4091015Courtesy of GENERAL MOTORS COMPANY
  14. Remove the EN-6015  plugs.
  15. Connect Fuel Feed Pipe (1). Refer to Plastic Collar Quick Connect Fitting Service 
    16. Fig 7: Evaporative Emission Rear Hose, Fuel Tank Filler Hose, Vent Pipe, Electrical Connector, Retainer And Clamp
    GM4091014Courtesy of GENERAL MOTORS COMPANY
  16. Install Fuel Tank Filler Hose (4)
    17. Fig 8: Ensure Filler Hose Is Fully Seated And Installed Correctly
    GM4217521Courtesy of GENERAL MOTORS COMPANY
  17. Make sure that the hose is fully seated on the fuel tank. Filler hose is correctly installed when the end of the hose is even with where the fill spud on the tank increases in diameter. The gap (1) between the tank and the end of hose will be (a) 6 mm (1/4 in) when hose is correctly installed.
    18. Fig 9: Evaporative Emission Rear Hose, Fuel Tank Filler Hose, Vent Pipe, Electrical Connector, Retainer And Clamp
    GM4091014Courtesy of GENERAL MOTORS COMPANY
  18. Tighten Clamp (5) to 3.5 N.m (31 lb in)
    19. Fig 10: Fuel Tank Filler Pipe Ground Bolt And Wiring Harness Clip
    GM4091061Courtesy of GENERAL MOTORS COMPANY
  19. Install and tighten Fuel Tank Filler Pipe Ground Bolt (1) to 9 N.m (80 lb in)
    20. Fig 11: Evaporative Emission Rear Hose, Fuel Tank Filler Hose, Vent Pipe, Electrical Connector, Retainer And Clamp
    GM4091014Courtesy of GENERAL MOTORS COMPANY
  20. Remove the EN-6015  plugs.
  21. Connect Fuel Tank Filler Vent Pipe (3). Refer to Plastic Collar Quick Connect Fitting Service 
  22. Close the retainer (6).
  23. Connect the fuel tank fuel pump module wiring harness electrical connector (2).
  24. Remove the EN-6015  plugs.
  25. Connect Evaporative Emission Rear Hose (1). Refer to Plastic Collar Quick Connect Fitting Service 
  26. Install Underbody Front Air Deflector - Left Side. Refer to Underbody Front Air Deflector Replacement - Left Side
  27. Install Underbody Rear Air Deflector. Refer to Underbody Rear Air Deflector Replacement
  28. Lower the vehicle.
  29. Refill the fuel tank.
  30. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection
  31. Cycle the ignition to run the fuel pump and check for fuel leaks.
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