GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2003 🢒 Regal 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 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) at 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 fuel feed, the fuel return and the evaporative emission (EVAP) pipes at the fuel filter area. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Support the exhaust system.
  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 fuel tank shield push pins (2).
  11. Remove the fuel tank shield (3).

    12. Object Number: 699556 Size: SH

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

  12. Support the fuel tank with a suitable jack.
  13. Remove the fuel tank strap bolts (2).
  14. Remove the fuel tank from the vehicle.
  15. Place the fuel tank in a suitable work area.

    16. Object Number: 531026 Size: SH
  16. Remove the fuel feed, the fuel return, and the EVAP pipe assemblies and the insulator clips from the fuel tank.
  17. Remove the EVAP canister from the fuel tank.
  18. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.

Installation Procedure

    Object Number: 531026 Size: SH
  1. Install the insulator pads to the fuel tank.
  2. Install the EVAP canister to the fuel tank.

    3. 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.

  3. Install the fuel feed, the fuel return, and the EVAP pipe assemblies and the insulator clips.

    4. Object Number: 699556 Size: SH
  4. Install the fuel tank to a suitable jack.
  5. Raise the fuel tank (1) to the original position.

    6. Notice: Refer to Fastener Notice in the Preface section.

  6. Install the fuel tank retaining strap bolts (2).

    7. Tighten
    Tighten the bolts to 48 N·m (35 lb ft).

  7. Remove the jack from the fuel tank.

    8. Object Number: 699555 Size: SH
  8. Position the fuel tank shield (3) to the fuel tank (1).
  9. Install the push pins (2).

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

    11. Object Number: 32401 Size: SH
  11. Connect the EVAP pipe, the fuel feed and the fuel return pipes at the front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .

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

    13. Object Number: 186674 Size: SH
  13. Fully seat the filler hose (4) on the fuel tank port (2).
  14. Ensure that the fuel tank filler pipe hose clamp (1) is properly located on the tank port between the bead (5) and the tank (3).

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

  15. Raise the exhaust system to the original position.
  16. Install the exhaust system to the exhaust pipe hangers.
  17. Lower the vehicle.
  18. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  19. Add fuel and install the fuel fill cap.
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  21. Inspect the fuel system for leaks by performing the following steps:
    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.
  22. Install fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.