Century, Grand Prix, Impala, Intrigue, Lumina, Monte Carlo, Regal 2001-2005

Removal & Installation

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3.4L Engine




NOTE
Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.


CAUTION
Always maintain cleanliness when servicing the fuel system components.

  1. Relieve the fuel system fuel pressure. Drain the fuel tank.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Loosen the fuel filler hose clamp at the fuel tank.
  6.  
  7. Remove the fuel tank filler hose from the fuel tank.
  8.  
  9. Disconnect the fuel feed and the return pipes at the fuel filter and the fuel filter area.
  10.  
  11. Disconnect the evaporative emission (EVAP) pipe from the connection at the front of the fuel tank.
  12.  
  13. Support the exhaust system.
  14.  
  15. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
  16.  
  17. Separate the two halves of the EVAP fresh air hose at the splice.
  18.  
  19. Remove the fuel tank shield push pins. Remove the fuel tank shield.
    NOTE
    Do not bend the fuel tank straps as this may damage the straps.

  20.  
  21. Support the fuel tank with a suitable jack.
  22.  
  23. Remove the fuel tank strap bolts.
  24.  
  25. Remove the fuel tank from the vehicle.
  26.  
  27. Place the fuel tank in a suitable work area. ]
  28.  
  29. Remove the EVAP canister.
  30.  
  31. Remove the fuel feed, the fuel return, and EVAP pipe assemblies and the insulator clips from the fuel tank.
  32.  
  33. Remove the insulator pad from the fuel tank. Note the location of the insulator pad for the installation.
  34.  

To install:


NOTE
Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle. Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes. Replace the vapor pipes with original equipment or parts that meet GM specifications. 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. Install the insulator pad on the fuel tank.
  2.  
  3. Install the fuel feed, the fuel return, and the EVAP pipe assemblies and the insulator clips.
  4.  
  5. Install the EVAP canister.
  6.  
  7. Install the fuel tank to a suitable jack.
  8.  
  9. Raise the fuel tank to the original position.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  10.  
  11. Install the fuel tank strap bolts and tighten to 35 ft. lbs, (48 Nm).
  12.  
  13. Position the fuel tank shield to the fuel tank.
  14.  
  15. Install the push pins.
  16.  
  17. Connect the EVAP pipe at the front of the fuel tank.
  18.  
  19. Connect the quick-connect fittings at the fuel filter and fuel filter area.
  20.  
  21. Install the two parts of the EVAP fresh air hose at the splice.
  22.  
  23. Install the fuel tank filler hose to the fuel tank.
  24.  
  25. Fully seat the filler hose on the fuel tank port.
  26.  
  27. Ensure that the clamp is properly located on the tank port between the bead and the tank. Tighten the hose clamp to 22 inch lbs (2.5 Nm).
  28.  
  29. Raise the exhaust system to the original position.
  30.  
  31. Install the exhaust system to the exhaust pipe hangers.
  32.  
  33. Lower the vehicle.
  34.  
  35. Install the fuel sender assembly.
  36.  
  37. Add fuel and install the fuel filler pipe cap.
  38.  
  39. Connect the negative battery cable.
  40.  
  41. Inspect the fuel system for leaks by performing the following steps:

    Turn ON the ignition for 2 seconds
     
    Turn OFF the ignition for 10 seconds
     
    Turn ON the ignition
     
    Inspect for fuel leaks
     

  42.  

3.5L, 3.8L, 3.9L & 5.3L Engines (Except 2005 5.3L Engine)




CAUTION
Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

  1. Relieve the fuel system fuel pressure.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Loosen the fuel fill hose clamp at the fuel tank.
  8.  
  9. Remove the fuel tank fill hose from the fuel tank.
  10.  
  11. Disconnect the EVAP vent solenoid hose on the tank from the EVAP vent valve solenoid hose.
  12.  
  13. Disconnect the EVAP vent pipe quick connect fitting from the fill pipe EVAP vent pipe quick connect fitting.
  14.  
  15. Disconnect the fuel feed, and the EVAP lines from the fuel tank lines.
  16.  
  17. Support the exhaust system.
  18.  
  19. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
  20.  
  21. Remove the fuel tank shield retainers.
  22.  
  23. Remove the fuel tank shield.
    NOTE
    Do not bend the fuel tank straps as this may damage the straps.

  24.  
  25. Support the fuel tank with a suitable adjustable jack.
  26.  
  27. Remove the fuel tank strap bolts.
  28.  
  29. Using the jack lower the fuel tank.
  30.  
  31. Disconnect the fuel sender jumper harness electrical connector.
  32.  
  33. Remove the fuel tank and place the tank in a suitable work area.
  34.  
  35. Disconnect and remove the fuel pressure sensor and fuel sender jumper harness electrical connectors.
    CAUTION
    Note the routing of the lines for installation.

  36.  
  37. Disconnect and remove the fuel feed line and the EVAP lines.
  38.  
  39. Remove the EVAP canister.
  40.  
  41. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.
  42.  

To install:


NOTE
Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle. Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes. Replace the vapor pipes with original equipment or parts that meet GM specifications. 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. Install the insulator pads to the fuel tank.
  2.  
  3. Install the EVAP canister.
  4.  
  5. Install and connect the fuel feed line and the EVAP lines.
  6.  
  7. Install and connect the fuel pressure sensor and fuel sender jumper harness electrical connectors.
  8.  
  9. Install the fuel tank onto a suitable jack.
  10.  
  11. Partially raise the fuel tank until the electrical connections can be made.
  12.  
  13. Connect the fuel sender jumper harness electrical connector.
  14.  
  15. Completely raise the tank.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  16.  
  17. Install the fuel tank strap bolts to 35 ft. lbs. (48 Nm).
  18.  
  19. Remove the jack from the fuel tank.
  20.  
  21. Position the fuel tank shield to the fuel tank.
  22.  
  23. Install the shield retainers.
  24.  
  25. Install the rubber exhaust pipe hangers.
  26.  
  27. Remove the support from the exhaust system.
  28.  
  29. Connect the fuel feed and EVAP lines to the fuel tank lines.
  30.  
  31. Connect the EVAP vent pipe quick connect fitting to the fill pipe EVAP vent pipe quick connect fitting.
  32.  
  33. Connect the EVAP vent solenoid hose on the tank to the EVAP vent valve solenoid hose.
  34.  
  35. Install the fuel tank fill hose onto the fuel tank. Install the hose over the orientation feature on the tank until fully seated to the tank. Tighten the clamp at the tank to 22 inch lbs. (2.5 Nm).
  36.  
  37. Lower the vehicle.
  38.  
  39. Add fuel and install the fuel fill cap.
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Inspect the fuel system for leaks by performing the following steps:

    Turn ON the ignition for 2 seconds
     
    Turn OFF the ignition for 10 seconds
     
    Turn ON the ignition
     
    Inspect for fuel leaks
     

  44.  
  45. Install the fuel injector sight shield.
  46.  

5.3L Engine




CAUTION
Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

  1. Relieve the fuel system fuel pressure.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Loosen the fuel fill hose clamp at the fuel tank.
  8.  
  9. Remove the fuel tank fill hose from the fuel tank.
  10.  
  11. Disconnect the EVAP vent pipe quick connect fitting from the fill pipe EVAP vent pipe quick connect fitting.
  12.  
  13. Disconnect the fuel feed, and the EVAP lines from the fuel tank lines.
  14.  
  15. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
  16.  
  17. Disconnect the fuel sender jumper harness electrical connector.
  18.  
  19. Remove the fuel tank shield retainers.
  20.  
  21. Remove the fuel tank shield.
    NOTE
    Do not bend the fuel tank straps as this may damage the straps.

  22.  
  23. Support the fuel tank with a suitable adjustable jack.
  24.  
  25. Remove the fuel tank strap bolts. Using the jack lower the fuel tank.
  26.  
  27. Disconnect the EVAP vent solenoid hose (2) on the tank from the EVAP vent valve solenoid hose.
  28.  
  29. Remove the fuel tank and place the tank in a suitable work area.
  30.  
  31. Disconnect and remove the fuel pressure sensor and fuel sender jumper harness electrical connectors.
    NOTE
    Note the routing of the lines for installation.

  32.  
  33. Disconnect and remove the fuel feed line and the EVAP lines.
  34.  
  35. Remove the EVAP canister.
  36.  
  37. Remove the insulator pads from the fuel tank.
  38.  
  39. Remove the fuel sender assembly.
  40.  

To install:


NOTE
Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle. Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes. Replace the vapor pipes with original equipment or parts that meet GM specifications. 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. Install the fuel sender assembly.
  2.  
  3. Install the insulator pads to the fuel tank.
  4.  
  5. Install the EVAP canister.
  6.  
  7. Install and connect the fuel feed line and the EVAP lines.
  8.  
  9. Install and connect the fuel pressure sensor and fuel sender jumper harness electrical connectors.
  10.  
  11. Install the fuel tank onto a suitable jack.
  12.  
  13. Partially raise the fuel tank until the electrical connections can be made.
  14.  
  15. Connect the fuel sender jumper harness electrical connector.
  16.  
  17. Completely raise the tank.
  18.  
  19. Install the fuel tank strap bolts and tighten to 35 ft. lbs. (48 Nm).
  20.  
  21. Remove the jack from the fuel tank.
  22.  
  23. Position the fuel tank shield to the fuel tank.
  24.  
  25. Install the shield retainers.
  26.  
  27. Install the rubber exhaust pipe hangers.
  28.  
  29. Remove the support from the exhaust system.
  30.  
  31. Connect the fuel feed and EVAP lines to the fuel tank lines.
  32.  
  33. Connect the EVAP vent pipe quick connect fitting to the fill pipe EVAP vent pipe quick connect fitting.
  34.  
  35. Connect the EVAP vent solenoid hose on the tank to the EVAP vent valve solenoid hose.
  36.  
  37. Install the fuel tank fill hose onto the fuel tank. Install the hose over the orientation feature on the tank until fully seated to the tank. Tighten the clamp to 22 inch lbs. (2.5 Nm).
  38.  
  39. Lower the vehicle. Add fuel and install the fuel fill cap.

    Turn ON the ignition for 2 seconds
     
    Turn OFF the ignition for 10 seconds
     
    Turn ON the ignition
     
    Inspect for fuel leaks
     

  40.  
  41. Install the fuel injector sight shield.
  42.  

 
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