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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 212 (Engine Controls - 2.2L (L61) Introduction) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the fuel pump module assembly to the fuel tank. Refer to Fuel Pump Module Replacement .
  2. With the aid of an assistant, raise the fuel tank (1) to the vehicle.
    Fig 1: Identifying Fuel Tank
    GM49897Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  3. Install the fuel tank retaining straps.

    Tighten:  Tighten the strap bolts to 35 N.m (26 lb ft).

  4. Connect the wiring harness into the multi-way rear body connector.
  5. Connect the EVAP vapor pipe to the EVAP canister.
  6. Connect the fuel filler hose to the fuel tank.

    Tighten:  Tighten the fuel filler hose clamp to 3 N.m (27 lb in).

  7. Install the rubber exhaust hangers.
  8. Install the exhaust heat shield.

    Tighten: 

    • Tighten the exhaust shield bolt to 2 N.m (18 lb in).
    • Tighten the exhaust shield nuts to 1 N.m (9 lb in).

  9. Connect the fuel return pipe and fuel filter quick-connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  10. Lower the vehicle.
  11. Refill the fuel tank.
  12. Install the fuel filler cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  14. 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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