GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Oldsmobile 🢒 2002 🢒 Intrigue 🢒 Engine 🢒 Engine Controls - 3.5L 🢒 Fuel Tank Replacement

Removal Procedure

    Notice: 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.

    Important: Always maintain cleanliness when servicing the fuel system components.

  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    4. Object Number: 186674 Size: SH
  4. Loosen the fuel filler hose clamp (1) from the fuel tank (3).

    5. Object Number: 155468 Size: SH
  5. Remove the fuel tank filler hose from the fuel tank.

    6. Object Number: 32401 Size: SH
  6. Disconnect the quick-connect fittings from the front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the evaporative emission (EVAP) pipe from the connection at the front of the fuel tank.
  8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.

    9. Object Number: 698635 Size: SH
  9. Separate the two halves of the EVAP fresh air hose at the splice.

    10. Object Number: 699555 Size: SH
  10. Remove the 3 push pins (2) and the fuel tank shield (3).

    11. Object Number: 699556 Size: SH

    Notice: Do not bend the fuel tank straps as this may damage the straps.

  11. Support the fuel tank (1) with a suitable transmission jack.
  12. Remove the fuel tank strap bolts (2).

    13. Object Number: 531026 Size: SH
  13. Lower the fuel tank to access the EVAP hose connections.

    14. Object Number: 230780 Size: SH
  14. Disconnect the EVAP pipes (4) from the rear of the fuel tank.
  15. Disconnect the EVAP pipe (2) from the fuel limiter vent valve.
  16. Disconnect the fuel filler neck EVAP pipe (3) at the rear of the fuel tank.
  17. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
  18. Remove the EVAP canister from the fuel tank.
  19. Disconnect the fuel feed, the fuel return, the EVAP pipe assemblies and the insulator clips from the fuel tank.

    20. Object Number: 12743 Size: SH
  20. Remove the insulator pad from the fuel tank. Note the location of the insulator pad for the installation.

Installation Procedure

    Object Number: 12743 Size: SH
  1. Install the insulator pad on the fuel tank.

    2. Object Number: 531026 Size: SH

    Notice: 

       • 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.

  2. Connect the fuel feed, the fuel return, the EVAP pipe assemblies and the insulator clips.
  3. Install the EVAP canister to the fuel tank.
  4. Install the fuel tank to a suitable transmission jack.

    5. Object Number: 230780 Size: SH
  5. Connect the EVAP pipes (4) to the rear of the fuel tank.
  6. Connect the EVAP pipe (2) to the fuel limiter vent valve.
  7. Connect the fuel filler EVAP pipe (3) at the rear of the fuel tank.
  8. Raise the fuel tank to the original position.

    9. Object Number: 699556 Size: SH

    Notice: 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.

  9. Install the fuel tank straps (3) and the bolts (2) to the fuel tank (1).

    10. Tighten
    Tighten the bolts to 47 N·m (35 lb ft).


    Object Number: 699555 Size: SH
  10. Install the fuel tank shield (3), and the 3 push pins (2).

    11. Object Number: 32401 Size: SH
  11. Connect the quick-connect fittings at the front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Connect the EVAP pipe at the front of the fuel tank.

    13. Object Number: 155468 Size: SH
  13. Install the fuel tank filler hose to the fuel tank.

    14. Object Number: 698635 Size: SH
  14. Connect the two parts of the EVAP fresh air hose at the splice.

    15. Object Number: 186674 Size: SH
  15. Ensure the clamp  (1) is properly located on tank port between the bead (5) and the tank (3).

    16. Tighten
    Tighten the hose clamp to 2.5 N·m (22  lb in).

  16. Install the exhaust pipe to the exhaust hangers.
  17. Lower the vehicle.
  18. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  19. Add fuel and install the fuel filler pipe cap.
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  21. Inspect for fuel leaks using the following procedure:
    22. 21.1. Turn ON the ignition for 2 seconds.
    21.2. Turn OFF the ignition for 10 seconds.
    21.3. Turn ON the ignition.
    21.4. Inspect for fuel leaks.