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Home >> Pontiac >> 2009 >> Vibe GT, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System & Fuel System - 2.4L (Lax) - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Fuel Tank Cushions & Fuel Tank
    GM2017147Courtesy of GENERAL MOTORS CORP.
  1. Install the new fuel tank cushions onto the fuel tank.
    2. Fig 2: Identifying Fuel Tank Vent Hose (AWD)
    GM2017146Courtesy of GENERAL MOTORS CORP.
  2. Install the fuel tank vent hose for AWD.
    3. Fig 3: View Of Fuel Tank Vent Hose & Fuel Tank Clamp (FWD)
    GM2016771Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel tank vent hose onto the fuel tube clamp for FWD.
    4. Fig 4: Identifying Fuel Tank Main Tube Sub-Assembly
    GM2016770Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel tank main tube sub-assembly.
  5. Install the fuel tank main tube onto the fuel tank.
  6. Install the fuel tank assembly for AWD.
  7. Set the fuel tank on a transmission jack.
    8. Fig 5: Holding Fuel Tank Using A Transmission Jack (AWD)
    GM2017132Courtesy of GENERAL MOTORS CORP.
  8. Operate the transmission jack, then install the fuel tank into the vehicle.
    9. Fig 6: Locating No. 1 Fuel Tank Bands Bolts
    GM2017134Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Caution .
  9. Install the 2 No. 1 fuel tank bands with the 4 bolts.

    Tighten:  39 N.m (29 lb ft)

  10. Install the fuel tank assembly for FWD.
  11. Set the fuel tank on a transmission jack.
    12. Fig 7: Holding Fuel Tank Using A Transmission Jack (FWD)
    GM2016766Courtesy of GENERAL MOTORS CORP.
  12. Operate the transmission jack, then install the fuel tank into the vehicle.
    13. Fig 8: Locating No. 1 Fuel Tank Bands Bolts
    GM2016768Courtesy of GENERAL MOTORS CORP.
  13. Install the 2 No. 1 fuel tank bands with the 4 bolts.

    Tighten:  39 N.m (29 lb ft)

    14. Fig 9: Identifying Correct Direction Of Hose Clamp
    GM2016791Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure that the hose clamp is facing in the correct direction when installing.
  14. Install the fuel tank filler pipe sub-assembly.
  15. Connect the fuel tank to filler pipe hose to the fuel tank.
    16. Fig 10: Exploded View Of Fuel Tank Filler Pipe Claw
    GM2017128Courtesy of GENERAL MOTORS CORP.
  16. Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
    17. Fig 11: Exploded View Of Fuel Tank Main Tube Sub-Assembly
    GM2017158Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
  17. Connect the fuel tank main tube sub-assembly.
  18. 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.
    19. Fig 12: Identifying Breather Tube Fuel Hose
    GM2016745Courtesy of GENERAL MOTORS CORP.
  19. Connect the breather tube fuel hose.
    20. Fig 13: Aligning Fuel Tube Connector With Pipe
    GM2016801Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
  20. 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.
  21. Install the checker onto the pipe.
    22. Fig 14: Exploded View Of Fuel Tank Vent Hose
    GM2016565Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
  22. Connect the fuel tank vent hose for Torsion Beam Type Suspension.
  23. 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.
  24. Slide the retainer of the fuel tube connector to lock the claws.
  25. Install the rear suspension member sub-assembly for Double Wishbone Type Suspension.
  26. Install the charcoal canister assembly.
    27. Fig 15: Identifying No. 2 Fuel Tank Protector Subassembly (AWD)
    GM2017123Courtesy of GENERAL MOTORS CORP.
  27. Install the No. 2 fuel tank protector with the 7 bolts for AWD.

    Tighten:  5.5 N.m (49 lb in)

    28. Fig 16: Locating Fuel Tank Protector Sub-Assembly Bolts (FWD)
    GM2016735Courtesy of GENERAL MOTORS CORP.
  28. Install the fuel tank protector sub-assembly with the 4 bolts for FWD.

    Tighten:  5.5 N.m (49 lb in)

    29. Fig 17: Locating Parking Brake Cables Bolts
    GM2017121Courtesy of GENERAL MOTORS CORP.
  29. Install the parking cables with the 4 bolts.

    Tighten:  5.4 N.m (48 lb in)

  30. Install the propeller with center bearing shaft assembly for AWD.
  31. Install the center exhaust pipe assembly for AWD.
  32. Install cthe enter exhaust pipe assembly for FWD.
  33. Add fuel.
  34. Install the right fuel sender gage assembly for AWD.
  35. Install the fuel suction tube assembly for AWD.
  36. Install the fuel suction tube assembly for FWD.
  37. Install the fuel pump gage retainer for AWD.
  38. Install the fuel pump gage retainer for FWD.
  39. Connect the fuel tank vent hose for FWD.
  40. Connect the fuel tank main tube sub-assembly.
    41. CAUTION: Refer to Fastener Caution .
  41. Connect the cable to the negative battery terminal.
  42. Inspect for a fuel leak.
  43. Inspect for an exhaust gas leak.
  44. Install no. 2 rear floor service hole cover for AWD.
  45. Install the rear floor service hole cover.
  46. Install the rear seat cushion assembly. Refer to Rear Seat Cushion Replacement .
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