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Home >> Pontiac >> 2004 >> Vibe Base, FWD, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System (Introduction) - 1.8L (LV6) >> Repair Instructions >> Fuel Tank Replacement (FWD) >> Installation Procedure

Installation Procedure

    Fig 1: Fuel Tank Straps, Fuel Tank And Bolts (FWD)
    GM853034Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank (3) to the vehicle.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the two fuel tank straps (2) to the vehicle with the four bolts (1).

    Tighten:  Tighten the bolts to 39 N.m (29 lb ft)

    3. Fig 2: Disconnecting/Connecting EVAP Vapor Line (FWD)
    GM853055Courtesy of GENERAL MOTORS CORP.
  3. Connect the EVAP vapor line (1) to the EVAP canister.
    4. Fig 3: Filler Pipe Vent Line And FLVV (FWD)
    GM853046Courtesy of GENERAL MOTORS CORP.
  4. Connect the filler pipe vent line (1) to the FLVV (2).
    5. Fig 4: ORVR Vent Line (FWD)
    GM853048Courtesy of GENERAL MOTORS CORP.
  5. Connect the ORVR vent line (1) to the FLVV.
    6. Fig 5: Filler Pipe Vent Line And Fuel Tank (FWD)
    GM853044Courtesy of GENERAL MOTORS CORP.
  6. Connect the filler pipe vent line (1) to the fuel tank (2).
    7. Fig 6: Fuel Filler Hose Clamp And Hose (FWD)
    GM853047Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel filler hose (2) to the fuel tank.
  8. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).
  9. Connect the fuel supply line. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    10. Fig 7: Parking Brake Cable And Bolts (Right) (FWD)
    GM853035Courtesy of GENERAL MOTORS CORP.
  10. Secure the parking brake cable (2) on the right side of the vehicle with 2 bolts (1).

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in).

    11. Fig 8: Parking Brake Cable And Bolts (Left) (FWD)
    GM853043Courtesy of GENERAL MOTORS CORP.
  11. Secure the parking brake cable (2) on the left side of the vehicle with 2 bolts (1).

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in).

    12. Fig 9: Rear Exhaust Heat Shield And Left/Right Side Bolts (FWD)
    GM850572Courtesy of GENERAL MOTORS CORP.
  12. Install the rear exhaust heat shield (2) to the vehicle underbody.
  13. Secure the rear exhaust heat shield (2) with the 2 left side bolts (1) and the 3 right side bolts (3).

    Tighten:  Tighten the bolts to 5.4 N.m (48 lb in).

  14. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle. Refer to Catalytic Converter Replacement (LV6 Engine) or Catalytic Converter Replacement (LNK Engine) in Engine Exhaust.
  15. Lower the vehicle.
    16. Fig 10: Fuel Tank Vapor Line, Fuel Supply Line And Retaining Clip (FWD)
    GM828313Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel tank vapor line (2) to the fuel sender fitting.
  17. Install the fuel supply line (3) to the fuel sender fitting.
  18. Secure the fuel supply line (3) with the retaining clip (1).
    19. Fig 11: FTP Sensor And Fuel Sender Electrical Connector (FWD)
    GM828297Courtesy of GENERAL MOTORS CORP.
  19. Connect the fuel sender electrical connector (1) to the fuel sender assembly.
  20. Connect the FTP sensor electrical connector (2) to the fuel sender assembly.
  21. Add fuel to the fuel tank.
  22. Connect the negative battery cable.

    Tighten:  Tighten the retainer for the negative battery cable terminal to 15 N.m (11 lb ft).

  23. Pressurize the fuel system and check for leaks.
  24. Inspect the butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
  25. Install the access panel to the rear seat floor.
  26. Relocate the carpet under the seat and the left sill plate area.
  27. Install the sill plate to the left side door opening.
  28. Install the rear seat bottom cushion. Refer to Seat Cushion Replacement - Rear in Seats.
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