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Home >> Pontiac >> 2010 >> G6 Base, 2D Coupe >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Control System & Fuel System - 2.4L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

    Fig 1: Fuel Tank Vapor Line
    GM1580730Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank is being replaced, perform the following:
    1. Install the fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement .
    2. Install the EVAP canister vent solenoid valve. Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
    3. Install the he EVAP canister. Refer to Evaporative Emission Canister Replacement .
    4. Install and connect the fuel tank vapor line. Refer to Plastic Collar Quick Connect Fitting Service .
    2. Fig 2: 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. 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. Fig 3: Fuel Tank, Straps & Bolts
    GM1578463Courtesy of GENERAL MOTORS CORP.
  5. Completely raise and install the fuel tank into position.
    6. NOTE: 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.
    CAUTION: Refer to Fastener Caution
  6. Install the fuel tank straps.
  7. Install the fuel tank strap bolts and tighten to 20 N.m(15 lb ft)..
  8. Remove the adjustable jack from under the fuel tank.
    9. Fig 4: Fuel Feed Line, Vapor Line & Quick Connect Fittings
    GM1580724Courtesy of GENERAL MOTORS CORP.
  9. Remove the caps or plugs from the fuel feed and vapor lines.
  10. Connect the fuel feed (2) and vapor (1) line quick connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .
    11. Fig 5: 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: Rear ABS Wiring Harness Connector
    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: 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: Fuel Fill Pipe Hose Clamp & Vapor Recirculation Line Quick Connect Fitting
    GM2146411Courtesy of GENERAL MOTORS CORP.
  16. Connect the fuel fill pipe hose to the fuel tank.
  17. Install the fuel fill pipe hose clamp (1) and tighten to 4 N.m(35 lb in).
  18. Connect the vapor recirculation line quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service .
  19. Position and connect the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement .
  20. Lower the vehicle.
  21. Refill the fuel tank.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  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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