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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 >> Removal Procedure

Removal Procedure

    Fig 1: Identifying Fuel Tank Hoses, Fittings & Clamps
    GM1578466Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Loosen the fuel fill pipe hose clamp (1) at the fuel tank.
  5. Disconnect the evaporative emission (EVAP) canister vent solenoid tube quick connect fitting (2). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  6. Disconnect the vapor recirculation line quick connect fitting (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Disconnect the fuel fill pipe hose from the fuel tank.
    8. Fig 2: View Of Exhaust Pipe Insulators At Underbody Hangers
    GM1275979Courtesy of GENERAL MOTORS CORP.
  8. Release the exhaust pipe insulators from the underbody hangers.
  9. Release the muffler insulator from the underbody hanger and slowly lower the exhaust to rest on a tall jackstand. If this is not possible, remove the rear half of the exhaust system at the take down flange.
    10. Fig 3: Identifying Rear Antilock Brake System (ABS) Wiring Harness Connector Clip
    GM1580941Courtesy of GENERAL MOTORS CORP.
  10. If applicable, disengage the rear antilock brake system (ABS) wiring harness connector clip from the side of the EVAP canister bracket.
    11. Fig 4: Identifying Fuel Tank Jumper Electrical Connector
    GM1580942Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the fuel tank jumper electrical connector from the underbody wiring harness.
  12. Disengage the underbody wiring harness connector clip from the EVAP canister bracket.
  13. Use an appropriate adjustable jack to support the fuel tank during removal.
    14. Fig 5: Identifying Fuel Tank Straps & Bolts
    GM1578463Courtesy of GENERAL MOTORS CORP.
  14. Remove the fuel tank strap bolts.
  15. Remove the fuel tank straps.
  16. Using the adjustable jack, lower the fuel tank slightly in order to access the fuel line connections.
    17. Fig 6: Identifying Fuel Feed Line, Vapor Line & Quick Connect Fittings
    GM1580724Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the fuel feed (2) and vapor (1) line quick connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  18. Cap or plug the fuel feed and vapor lines in order to prevent fuel loss and/or system contamination.
  19. In order to clear the exhaust pipe, slowly lower the right side of the fuel tank.
  20. Once the tank is clear of the right frame rail, remove the fuel tank down and forward toward the right side of the vehicle.
    21. Fig 7: Identifying Fuel Tank Electrical Harness
    GM1580732Courtesy of GENERAL MOTORS CORP.
  21. If the fuel tank is being replaced, disconnect and remove the fuel tank electrical harness.
    22. Fig 8: View Of Fuel Tank External Attachments
    GM1580730Courtesy of GENERAL MOTORS CORP.
  22. If the fuel tank is being replaced, perform the following:
    1. Disconnect and remove the fuel tank vapor line. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    2. Remove the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
    3. Remove the EVAP canister vent solenoid valve. Refer to Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement .
    4. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement .
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