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Home >> Pontiac >> 2008 >> G8 Base >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System & Fuel System - 3.6L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

  1. Install the following components if fuel tank replacement was necessary.
    2. IMPORTANT: Make sure the following are properly routed while raising the fuel tank:
    • The fuel tank wiring harness.
    • The fuel hoses at the chassis pipes.
    Fig 1: Identifying Fuel Tank Strap To Chassis Retaining Bolts
    GM1949817Courtesy of GENERAL MOTORS CORP.
  2. With the aid of an assistant, carefully raise the fuel tank to the vehicle.
    3. IMPORTANT: Make sure the fuel tank straps are not pressed into the fuel tank.
  3. Carefully install the fuel tank straps back to their original form.
  4. Position the fuel tank straps around the rear frame and upward into position, aligning the holes in the straps with the threaded holes in the chassis.
    5. NOTE: Refer to Fastener Notice .
  5. Install the fuel tank strap bolts.

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

    6. Fig 2: Identifying Evaporative Emission Line & Canister
    GM2008604Courtesy of GENERAL MOTORS CORP.
  6. Connect the evaporative emission line (2) to the evaporative emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service .
    7. Fig 3: View Of Support Tool
    GM1949823Courtesy of GENERAL MOTORS CORP.
  7. Raise the rear frame assembly using suitable tool.
    8. Fig 4: View Of EN-48536
    GM2008605Courtesy of GENERAL MOTORS CORP.
  8. Remove the special tool EN-48536  bolt (1) from the rear frame. Repeat for the opposite side.
    9. Fig 5: Identifying EN-48536
    GM2008606Courtesy of GENERAL MOTORS CORP.
  9. Remove the special tool EN-48536  bolt (1) from the rear frame. Repeat for the opposite side.
  10. Using a suitable tool clean the threaded holes in the rear chassis.
    11. Fig 6: Identifying Rear Frame To Chassis Retaining Bolts
    GM1949819Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Rear frame retaining bolts must not to be fully tightened at this stage.
  11. Install the NEW rear frame to chassis retaining bolts (2).

    Do not fully tighten at this stage.

  12. After retaining bolts (1 and 2) are installed tighten to.

    Tighten: 

    • First Pass: Tighten the bolts to 65 N.m (48 lb ft)
    • Final Pass: Tighten the bolts a further 125 degrees.

    13. Fig 7: View Of Support Tool
    GM1949823Courtesy of GENERAL MOTORS CORP.
  13. Remove the support tool.
    14. Fig 8: Identifying Fuel Tank Electrical Connector
    GM1949816Courtesy of GENERAL MOTORS CORP.
  14. Connect the fuel tank electrical connector (1).
    15. Fig 9: Identifying Fuel Feed Line & Fuel EVAP Hose
    GM1949815Courtesy of GENERAL MOTORS CORP.
  15. Refer to Plastic Collar Quick Connect Fitting Service , in order to connect the following to the chassis bundle:
    • The fuel feed line
    • The fuel EVAP hose
    16. Fig 10: Identifying Evaporative Emission (EVAP) Line
    GM1949829Courtesy of GENERAL MOTORS CORP.
  16. Install the evaporative emission (EVAP) line (1), listen for an audible click to confirm fitting.
    17. Fig 11: Identifying Filler Hose
    GM1949831Courtesy of GENERAL MOTORS CORP.
  17. Connect the filler hose (2) to the fuel tank.

    Tighten:  Tighten the fuel filler tube hose clamp (1) to 4 N.m (35 lb in).

  18. Connect the park brake rear cables to the park brake front cable equalizer bracket assembly. Refer to Parking Brake Front Cable Replacement .
  19. Install the propeller shaft. Refer to Propeller Shaft Replacement .
  20. Install the exhaust system. Refer to Exhaust System Replacement (LY7) .
  21. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation .
  22. Refill the fuel tank.
  23. Inspect for fuel leaks.
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