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Home >> Pontiac >> 2005 >> Vibe Base, AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 1.8L (LV6) - Introduction >> Repair Instructions >> Fuel Tank Replacement (FWD) >> Installation Procedure

Installation Procedure

    Fig 1: Fuel Tank, Fuel Tank Strap And Bolts
    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 2 fuel tank straps (2) to the vehicle with the 4 bolts (1).

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

    3. Fig 2: Fuel Filler Hose And Clamp
    GM853047Courtesy of GENERAL MOTORS CORP.
  3. Connect the fuel filler hose (2) to the fuel tank.
  4. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).
    5. Fig 3: Removing Fuel Supply Line
    GM853058Courtesy of GENERAL MOTORS CORP.
  5. Connect the fuel supply line. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  6. Connect the fuel tank vapor line with the quick release fitting to the fuel vapor pipe. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Connect the ORVR vent line to the FLVV on the EVAP canister.
    8. Fig 4: Parking Brake Cable And Bolts On Right Side
    GM853035Courtesy of GENERAL MOTORS CORP.
  8. 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).

    9. Fig 5: Rear Exhaust Heat Shield, Left Side And Right Side Bolts
    GM850572Courtesy of GENERAL MOTORS CORP.
  9. Install the rear exhaust heat shield (2) to the vehicle underbody.
  10. 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).

  11. 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.
  12. Lower the vehicle.
  13. If the fuel sender assembly was removed refer to Fuel Sender Assembly Replacement (FWD)  or Fuel Sender Assembly Replacement (AWD) .
    14. Fig 6: ORVR Vent Line And Fuel Sender Assembly
    GM1460719Courtesy of GENERAL MOTORS CORP.
  14. Connect the ORVR vent line (2) to the fuel sender assembly (1).
    15. Fig 7: Quick Connect Clasp And ORVR Vent Line
    GM1465470Courtesy of GENERAL MOTORS CORP.
  15. Slide the quick connect clasp (1) into the lock position on the ORVR vent line (2).
    16. Fig 8: Fuel Sender Assembly Fuel Line
    GM1460705Courtesy of GENERAL MOTORS CORP.
  16. Connect the fuel supply line (1) to the fuel sender assembly.
    17. Fig 9: Fuel Supply Line Retaining Clip
    GM1465471Courtesy of GENERAL MOTORS CORP.
  17. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).
    18. Fig 10: Fuel Sender Assembly Electrical Connector
    GM1460703Courtesy of GENERAL MOTORS CORP.
  18. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
  19. Add fuel to the fuel tank.
  20. Connect the negative battery cable.

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

  21. Pressurize the fuel system and check for leaks.
  22. Install the access panel (1) to the rear seat floor panel (3).
  23. Secure the access panel to the body with 4 bolts.

    Tighten:  Tighten the 4 bolts to 6 N.m (53 lb in).

  24. Relocate the carpet under the ride side seat area and the right sill plate area.
  25. Install the sill plate to the right side door opening.
    26. Fig 11: Rear Seat Bottom Cushion And Bolts
    GM1464194Courtesy of GENERAL MOTORS CORP.
  26. Lower the rear seat bottom cushion (1) and secure with 2 bolts (2).

    Tighten:  Tighten the 2 bolts to 41 N.m (30 lb ft).

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