GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Tank Assembly

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CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

The aid of an assistant is required to perform this procedure.

REMOVAL & INSTALLATION



1985-91 Vehicles

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: View of the fuel tank mounting-1991 vehicle

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Remove the fuel filler door assembly and disconnect the screw retaining the filler pipe-to-body bracket.
  6.  
  7. Raise and safely support the vehicle with jackstands.
  8.  
  9. Detach the tank level sender lead connector.
  10.  
  11. If equipped, remove the ground wire retaining screw from the underbody of the vehicle.
  12.  
  13. Disconnect the hoses from the tank meter assembly and the hoses at the tank from the filler and vent pipes.
  14.  
  15. Support the tank with a transmission jack or equivalent.
  16.  
  17. Unfasten the two tank retaining straps, then remove the tank from the vehicle slowly to ensure all connections and hoses have been detached.
  18.  

To install:
  1. Position the tank sound insulators in their original positions and raise the tank far enough to connect the electrical and hose connectors.
  2.  
  3. Raise the tank to the proper position and loosely install the retaining straps. Make sure the tank is in the proper position before tightening the retaining straps. Tighten the strap bolts to 25 ft. lbs. (33 Nm) and the nuts to 106 inch lbs. (12 Nm).
  4.  
  5. Connect the hoses to the fuel tank meter assembly and the filler and vent pipes. Tighten the clamps.
  6.  
  7. If equipped, connect the grounding lead to the underbody of the car.
  8.  
  9. Attach the fuel tank meter assembly harness connector to the body harness connector.
  10.  
  11. Lower the car, install the filler pipe-to-body bracket and the fuel filler door.
  12.  
  13. Connect the negative battery cable, then fill the gas tank with fuel.
  14.  
  15. With the engine OFF, turn the ignition key to the ON position and check for fuel leaks at the tank.
  16.  

1992-98 Vehicles

See Figure 2

Two people are required to perform this procedure.

  1. Disconnect the negative battery cable.
  2.  
  3. Properly drain the fuel tank.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Detach the fuel sender connector.
  8.  
  9. Unfasten the muffler hanger bolts.
  10.  
  11. Remove the exhaust rubber hangers and allow the exhaust system to rest on the rear axle.
  12.  
  13. Use compressed air to blow any dirt away from all hoses and fittings prior to tank removal.
  14.  
  15. Disconnect the hoses from the fuel tank sender. For details, please refer to quick-connect fitting removal, located in this section.
  16.  
  17. Detach the hoses, at the tank, from the filler, vent and vapor pipes.
  18.  
  19. With an assistant's help, support the tank, then unfasten the two fuel tank retaining straps. Remove the tank from the vehicle slowly to ensure all connections and hoses have been detached.
  20.  
  21. Remove the hoses from the sending unit, be sure to label them.
  22.  
  23. Remove the sound insulators.
  24.  
  25. Remove the sending unit from the tank.
  26.  
  27. Inspect the fuel line O-rings for damage, and replace if necessary.
  28.  



Click image to see an enlarged view

Fig. Fig. 2: Common fuel tank mounting-1992-98 models

To install:
  1. Inspect all connectors for dirt and burrs.
  2.  
  3. Install the sending unit in the fuel tank. Refer to Fuel Pump Removal and Installation.
  4.  
  5. Install the sound insulators.
  6.  
  7. With an assistant's help, position the fuel tank to the body of the car and secure using the retaining straps. Do not tighten them completely at this time.
  8.  
  9. Attach the fuel feed and return connecting line quick-connect fittings to the fuel sender. Apply a few drops of clean engine oil to the male ends of the fuel lines before connection. Push all connectors together to cause the retaining tabs to snap into place. Once connected, pull both ends of each connection to make sure they are secure.
  10.  
  11. Connect the hoses to the filler, vent and vapor pipes.
  12.  
  13. Attach the sending unit wiring.
  14.  
  15. Secure the fuel tank and tighten the strap bolts to 26 ft. lbs. (35 Nm).
  16.  
  17. Install the exhaust rubber hangers, then secure the muffler hanger bolts. Tighten the bolts to 11 ft. lbs. (15 Nm).
  18.  
  19. Carefully lower the vehicle, then refill the fuel tank.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Check for leaks through the following:
    1. Turn the ignition to the ON position for two seconds.
    2.  
    3. Turn it the ignition switch to the OFF position for ten seconds.
    4.  
    5. Turn again to the ON position and check for fuel leaks.
    6.  

  24.  

 
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