Installation Procedure

WARNING: This page is about a different car, the 2005 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Fuel Tank - Left

Courtesy of GENERAL MOTORS CORP.

Install the fuel tank.
Install the fuel tank strap to the vehicle.

Fig 2: Fuel Tank Strap Mount, Cover, Screws & Bolts

Courtesy of GENERAL MOTORS CORP.

Install the fuel tank strap bolts loosely leaving the tank hanging approximately one inch.
Remove the cap from the EVAP pipe.

Fig 3: EVAP Crossover Pipe & Tank Crossover Hose

Courtesy of GENERAL MOTORS CORP.

Connect the EVAP crossover pipe (2) quick connect fitting at the left fuel tank.

Fig 4: View Of Crossover Tube To Fuel Tank O-Rings & Alignment Feature

Courtesy of GENERAL MOTORS CORP.

Lubricate the crossover tube to fuel tank connection O-rings (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.

IMPORTANT: Note the location of the T-shaped alignment feature (5) between the jet pump feed/return pipes connector.

Fig 5: View Of Crossover Tube

Courtesy of GENERAL MOTORS CORP.

Lubricate the crossover tube O-ring mating surfaces (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.

IMPORTANT: Note the T-shaped alignment feature on the crossover tube.

IMPORTANT: The crossover tube will not fully seat into the fuel tank if the jet pump lines are misaligned.

Connect the crossover tube to the left fuel tank using the features previously noted.

IMPORTANT: The crossover tube collar tangs will not latch if misalignment exists.

Rotate the crossover tube collar (3) clockwise to engage the tangs.

Fig 6: Locating Air Inlet Hose

Courtesy of GENERAL MOTORS CORP.

Rotate the crossover tube CPA retainer counterclockwise past the collar latching tang and push the tab (1) into the locked position.

IMPORTANT: If the CPA retainer is locked into position, the crossover tube collar will not rotate.

Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.

Fig 7: Fuel Tank Strap Mount, Cover, Screws & Bolts

Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

Tighten the fuel tank strap bolts.
Tighten: Tighten the bolts to 25 N.m (18 lb in).
Remove the cap from the fuel pipes.

Fig 8: Locating Fuel Feed Pipe

Courtesy of GENERAL MOTORS CORP.

Connect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

Fig 9: View Of Fuel Pump Jumper Harness Connector

Courtesy of GENERAL MOTORS CORP.

Connect the fuel pump jumper harness connector.
Connect the fuel fill hose and recirc line to the fill tube.
Tighten: Tighten the clamp to 4 N.m (35 lb in).
Install the driveline support assembly. Refer to Driveline Support Assembly Replacement (Manual Transmission) or Driveline Support Assembly Replacement (Automatic Transmission) in Propeller Shaft.
Install both mufflers. Refer to Muffler Replacement - Left and Muffler Replacement - Right in Engine Exhaust.
Install the left rear wheelhouse panel. Refer to Wheelhouse Liner Panel Replacement - Rear in Body Rear End.
Install the Left rear tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
Lower the vehicle.
Refuel the fuel tank.
Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (7.0L) in Engine Electrical.
Perform the following procedure in order to test for leaks:
1. Turn ON the ignition switch for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.
Program the transmitters. Refer to Transmitter Programming (Domestic and Japan) or Transmitter Programming (Export - Including Canada) in Keyless Entry.