Solstice 2006-2008, Sky 2007-2008

Removal & Installation

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CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


CAUTION
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
    NOTE
    Ensure that the fuel tank is completely drained because of the severe angle that the tank will need to be tipped, in order to remove the tank.

  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the fuel tank.
  8.  
  9. Remove the rear compartment trim panel.
  10.  
  11. Remove the fuel pump module access cover bolts.
  12.  
  13. Remove the fuel pump module access cover.
  14.  
  15. Disconnect the fuel sending unit electrical connector.
  16.  
  17. Disconnect the fuel tank pressure sensor electrical connector.
  18.  
  19. Disconnect the Evaporative Emission (EVAP) canister vent solenoid electrical connector.
  20.  
  21. Disconnect the fuel pump fuel feed line quick connect fitting .
  22.  
  23. Disconnect the EVAP canister purge line quick connect fitting from the module.
  24.  
  25. Secure the fuel feed and EVAP purge lines up out of the way.
  26.  
  27. Remove the fuel fill pipe.
  28.  
  29. Disconnect the fuel tank fill pipe EVAP line quick connect fitting (1) from the module.
  30.  
  31. Remove the fuel tank fill EVAP line out through the access hole in order to prevent damage to the pipe when removing the tank.
  32.  
  33. Remove the rear suspension crossmember.
  34.  
  35. Remove the stabilizer shaft.
  36.  
  37. Position an adjustable jack under the fuel tank.
  38.  
  39. Remove the fuel tank strap/support bolts. 
  40.  
  41. Remove the fuel tank support bolts.
  42.  
  43. Remove the fuel tank supports. 
  44.  
  45. Remove the adjustable jack from under the fuel tank and with the aid of an assistant, tilt the tank down towards the left side of the vehicle and carefully remove the tank.
  46.  
  47. Place the fuel tank onto a suitable work surface.
  48.  
  49. Cap or plug the fuel feed and EVAP lines in order to prevent fuel loss and/or system contamination.
  50.  

To install:

  1. Remove the caps or plugs from the fuel feed and EVAP lines.
  2.  
  3. With the aid of an assistant tilt the tank up and carefully install the tank in from the left side of the vehicle.
  4.  
  5. Position an adjustable jack under the fuel tank.
  6.  
  7. Position the fuel tank supports.
  8.  
  9. Install the fuel tank strap/support bolts and tighten to 16 ft. lbs. (22 Nm).
  10.  
  11. Install the fuel tank support bolts and tighten to 16 ft. lbs. (22 Nm).
  12.  
  13. Remove adjustable jack from under the fuel tank.
  14.  
  15. Install the stabilizer shaft.
  16.  
  17. Install the rear suspension crossmember.
  18.  
  19. Install the fuel tank fill EVAP line in through the access hole.
  20.  
  21. Connect the fuel tank fill pipe EVAP line quick connect fitting to the module.
  22.  
  23. Install the fuel fill pipe.
  24.  
  25. Unsecure the fuel feed and EVAP purge lines and position to the module.
  26.  
  27. Connect the EVAP canister purge line quick connect fitting to the module.
  28.  
  29. Connect the fuel pump fuel feed line quick connect fitting to the module.
  30.  
  31. Connect the EVAP canister vent solenoid electrical connector.
  32.  
  33. Connect the fuel tank pressure sensor electrical connector.
  34.  
  35. Connect the fuel sending unit electrical connector.
  36.  
  37. Install the pump module access cover.
  38.  
  39. Install the fuel pump module access cover bolts and tighten to 89 inch. lbs. (10 Nm).
  40.  
  41. Install the rear compartment trim panel.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Inspect for leaks using the following procedures:

    Turn ON the ignition, with the engine OFF for 2 seconds.
     
    Turn OFF the ignition for 10 seconds.
     
    Turn ON the ignition, with the engine OFF.
     
    Inspect for fuel leaks.
     

  46.  

 
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