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Home >> Pontiac >> 2006 >> G6 Base, 2.4 B >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 2.4L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Fuel Tank External Attachments
    GM1580730Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank is being replaced, perform the following:
    1. Install the fuel sender. Refer to Fuel Sender Assembly Replacement .
    2. Install the EVAP canister vent solenoid valve. Refer to Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement .
    3. Install the he EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
    4. Install and connect the fuel tank vapor line. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    2. Fig 2: Identifying Fuel Tank Electrical Harness
    GM1580732Courtesy of GENERAL MOTORS CORP.
  2. If the fuel tank is being replaced, install and connect the fuel tank electrical harness.
    3. Fig 3: Identifying Fuel Feed Line, Vapor Line & Quick Connect Fittings
    GM1580724Courtesy of GENERAL MOTORS CORP.
  3. Begin to install the left side of the fuel tank over the exhaust pipe.
  4. Raise the right side of the fuel tank into position inboard of the right frame rail. Use care in feeding the fuel feed, EVAP vapor line and the fuel sender electrical harness over the exhaust system.
  5. Remove the caps or plugs from the fuel feed and vapor lines.
  6. Connect the fuel feed (2) and vapor (1) line quick connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. Fig 4: Identifying Fuel Tank Straps & Bolts
    GM1578463Courtesy of GENERAL MOTORS CORP.
  7. Completely raise and install the fuel tank into position.
    8. IMPORTANT: Ensure that the strap marked with the "L" is installed on the left side and the strap marked "R" is installed on the right side.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the fuel tank straps.
  9. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

  10. Remove the adjustable jack from under the fuel tank.
    11. Fig 5: Identifying Fuel Tank Jumper Electrical Connector
    GM1580942Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel tank jumper electrical connector to the underbody wiring harness.
  12. Engage the underbody wiring harness connector clip to the EVAP canister bracket.
    13. Fig 6: Identifying Rear Antilock Brake System (ABS) Wiring Harness Connector Clip
    GM1580941Courtesy of GENERAL MOTORS CORP.
  13. If applicable, engage the rear ABS wiring harness connector clip to the side of the EVAP canister bracket.
    14. Fig 7: View Of Exhaust Pipe Insulators At Underbody Hangers
    GM1275979Courtesy of GENERAL MOTORS CORP.
  14. Raise the exhaust into position and install the muffler insulator to the underbody hanger.
  15. Install the exhaust extension pipe insulators to the underbody hangers.
    16. Fig 8: Identifying Fuel Tank Hoses, Fittings & Clamps
    GM1578466Courtesy of GENERAL MOTORS CORP.
  16. Connect the fuel fill pipe hose to the fuel tank.
  17. Tighten the fuel fill pipe hose clamp (1) at the fuel tank.

    Tighten:  Tighten the clamp to 4 N.m (35 lb in).

  18. Connect the EVAP canister vent solenoid tube quick connect fitting (2). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  19. Connect the vapor recirculation line quick connect fitting (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  20. Lower the vehicle.
  21. Refill the fuel tank.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  23. Inspect for fuel leaks using the following procedure:
    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.
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