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Fuel Tank: Installation

WARNING: This page is about a different car, the 2003 Pontiac Grand Prix, 2003 Chevrolet Monte Carlo, 2003 Chevrolet Impala, 2003 Buick Regal, and 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the hose.
  1. Position and support the fuel tank with the aid of an assistant. Connect the fuel sender and the fuel tank pressure sensor electrical connectors. Install the fuel tank straps. Install the fuel tank strap bolts. Tighten the fuel tank strap bolts to specification. See TORQUE SPECIFICATIONS .
  2. Position the tank shield, and install the three push pins. Connect the quick-connect fittings at the fuel filter and chassis. Connect the EVAP pipe at the front of the fuel tank. Connect the fuel tank filler hose to the fuel tank. Connect the filler vent pipe at the filler hose/pipe connection.
  3. Connect the two parts of the EVAP fresh air hose at the splice. Fully seat the filler hose on fuel tank port. Make sure clamp is properly located on tank port between the bead and tank. See Figure.
  4. Tighten the fuel tank filler pipe hose clamp to specification. Install the rubber exhaust pipe hangers. Lower the vehicle. Add fuel and install the fuel filler pipe cap. Connect the negative battery cable. Inspect for fuel leaks using the following procedure. Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.


  1. Install the fuel tank to a suitable jack. Install the fuel tank straps. Install the fuel tank retaining strap bolts. Tighten the fuel tank retaining strap bolts to specification. See TORQUE SPECIFICATIONS . Remove the jack from the fuel tank.
  2. Connect the fuel tank electrical connector. Install the fuel tank electrical harness into the retainers. Install the fuel and EVAP retainer to the frame. Connect the EVAP pipe (2) to the EVAP canister.
  3. Connect the fuel filler hose (4) to the fuel filler pipe. See, TORQUE SPECIFICATIONS . Install the wheelhouse filler pipe opening cover.
  4. Lower the vehicle. Add fuel and install the fuel fill cap. Connect the negative battery cable. Inspect for fuel leaks using the following procedure. Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks. Install fuel injection sight shield.
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