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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 >> Removal Procedure

Removal Procedure

    Fig 1: Fuel Fill Pipe Hose Clamp & Vapor Recirculation Line Quick Connect Fitting
    GM2146411Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027)  or Fuel Pressure Relief (Without CH 48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining (Non E-85) .
  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 and reposition the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement .
  6. Disconnect the vapor recirculation line quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the fuel fill pipe hose from the fuel tank.
    8. Fig 2: 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: Rear ABS Wiring Harness Connector
    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: 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. Fig 5: Fuel Tank, Straps & Bolts
    GM1578463Courtesy of GENERAL MOTORS CORP.
  13. Use an appropriate adjustable jack to support the fuel tank during removal.
  14. Remove the fuel tank strap bolts.
  15. Remove the fuel tank straps.
    16. Fig 6: Fuel Feed Line, Vapor Line & Quick Connect Fittings
    GM1580724Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the fuel feed (2) and vapor (1) line quick connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .
  17. Cap or plug the fuel feed and vapor lines in order to prevent fuel loss and/or system contamination.
  18. In order to clear the exhaust pipe, slowly lower the right side of the fuel tank.
  19. Once the tank is clear of the right frame rail, remove the fuel tank down and forward toward the right side of the vehicle.
    20. Fig 7: Fuel Tank Electrical Harness
    GM1580732Courtesy of GENERAL MOTORS CORP.
  20. If the fuel tank is being replaced, disconnect and remove the fuel tank electrical harness.
    21. Fig 8: Fuel Tank Vapor Line
    GM1580730Courtesy of GENERAL MOTORS CORP.
  21. If the fuel tank is being replaced, perform the following:
    1. Disconnect and remove the fuel tank vapor line. Refer to Plastic Collar Quick Connect Fitting Service .
    2. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .
    3. Remove the EVAP canister vent solenoid valve. Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
    4. Remove the fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement .
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