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Home >> Pontiac >> 2009 >> Vibe Base, 1.8 8, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System & Fuel System - 1.8L (Lay) - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Fuel Tank Cushions & Fuel Tank
    GM2016779Courtesy of GENERAL MOTORS CORP.
  1. Install the new fuel tank cushions onto the fuel tank.
    2. Fig 2: Identifying Fuel Tank Vent Hose & Fuel Tank Clamp
    GM2016771Courtesy of GENERAL MOTORS CORP.
  2. Install the fuel tank vent hose onto the fuel tube clamp.
    3. Fig 3: View Of Fuel Tank Main Tube & Fuel Tank
    GM2016770Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel tank main tube onto the fuel tank.
  4. Set the fuel tank on a transmission jack.
    5. Fig 4: Holding Fuel Tank Using A Transmission Jack
    GM2016766Courtesy of GENERAL MOTORS CORP.
  5. Operate the transmission jack, then install the fuel tank into the vehicle.
  6. Install the 2 No. 1 fuel tank bands with the 4 bolts.

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

    7. Fig 5: Identifying Correct Hose Clamp Direction
    GM2016791Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure that the hose clamp is facing in the correct direction when installing.
  7. Connect the fuel tank filler pipe to the fuel tank.
    8. Fig 6: Engaging Fuel Tank Filler Pipe Claw
    GM2016793Courtesy of GENERAL MOTORS CORP.
  8. Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
    9. Fig 7: Fuel Tank Main Tube
    GM2016794Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work. After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector and pipe.
  9. Connect the fuel tank main tube.
  10. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
    11. Fig 8: Identifying Fuel Breather Tube Fuel Hose
    GM2016745Courtesy of GENERAL MOTORS CORP.
  11. Connect the breather tube fuel hose.
    12. Fig 9: Aligning Fuel Tube Connector With Pipe
    GM2016801Courtesy of GENERAL MOTORS CORP.
  12. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather tube to the pipe.
  13. Install the checker onto the pipe.
    14. Fig 10: Fuel Tank Vent Hose.
    GM2016565Courtesy of GENERAL MOTORS CORP.
  14. Connect the fuel tank vent hose.
  15. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
  16. Slide the retainer of the fuel tube connector to lock the claws.
  17. Install the charcoal canister assembly. Refer to Evaporative Emission Canister Replacement .
    18. Fig 11: Locating No. 1 Fuel Tank Protector Sub-Assembly Bolts
    GM2016735Courtesy of GENERAL MOTORS CORP.
  18. Install the fuel tank protector sub-assembly with the 4 bolts.

    Tighten:  Tighten the bolts to 5.5 N.m (49 lb in).

    19. Fig 12: Identifying Parking Brake Cables Bolts
    GM2016736Courtesy of GENERAL MOTORS CORP.
  19. Install the parking cables with the 4 bolts.
  20. Install the front exhaust pipe assembly. Refer to Exhaust Pipe Replacement (1.8L)
  21. Add fuel.
  22. Install the fuel sender gage sub-assembly.
  23. Install the fuel suction tube assembly.
  24. Install the fuel pump gage retainer.
  25. Connect the fuel tank vent hose.
  26. Connect the fuel tank main tube sub-assembly.
    27. CAUTION: Refer to Battery Disconnect Warning .
  27. Connect the cable to the negative battery terminal.
  28. Inspect for a fuel leak.
  29. Inspect for a exhaust gas leak.
  30. Install the rear floor service hole cover.
  31. Install the rear seat cushion assembly. Refer to Rear Seat Cushion Replacement .
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