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Home >> Pontiac >> 2004 >> Bonneville GXP >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls (Introduction) -- 4.6L (LD8) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

  1. Position and support the fuel tank (5) with the aid of an assistant.
  2. Install the fuel tank straps (2).
    Fig 1: Fuel Tank & Strap Bolts
    GM104646Courtesy of GENERAL MOTORS CORP.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel tank strap bolts (4).

    Tighten:  Tighten the fuel tank strap bolts to 46 N.m (34 lb ft).

    4. Fig 2: Fuel Tank Electrical Connector
    GM684415Courtesy of GENERAL MOTORS CORP.
  4. Connect the fuel tank electrical connector.
  5. Install the fuel tank electrical harness into the retainers.
    6. Fig 3: EVAP Retainer, Fuel & Frame
    GM684413Courtesy of GENERAL MOTORS CORP.
  6. Install the fuel and EVAP retainer to the frame.
    7. Fig 4: View Of EVAP Pipe To Canister
    GM104621Courtesy of GENERAL MOTORS CORP.
  7. Connect the EVAP pipe (2) to the EVAP canister.
    8. Fig 5: View Of Fuel Filter Quick Connections
    GM483018Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel feed pipe (4) and the fuel return pipe (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    9. Fig 6: Wheel House Filler Pipe Opening Cover
    GM614282Courtesy of GENERAL MOTORS CORP.
  9. Install the rear suspension support assembly. Refer to Support Replacement in Rear Suspension.
  10. Connect the fuel filler hose to the fuel filler pipe.

    Tighten:  Tighten the clamp to 4.2 N.m (37 lb in).

  11. Install the wheelhouse filler pipe opening cover (2).
  12. Lower the vehicle.
  13. Add fuel to the fuel tank.
  14. Install the fuel tank filler pipe cap.
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  16. 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.
  17. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.
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