GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2004 🢒 Rendezvous - AWD 🢒 Engine 🢒 Engine Controls - 3.6L (LY7) 🢒 Fuel Tank Replacement

Removal Procedure

    Important: Always maintain cleanliness when servicing 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 the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    4. Object Number: 680801 Size: SH
  4. Disconnect the fuel tank wiring harness connector (1).

    5. Object Number: 1404183 Size: SH
  5. Disconnect the fuel evaporative emission (EVAP) pipes. Refer to Plastic Collar Quick Connect Fitting Service .

    6. Object Number: 669530 Size: SH
  6. Remove the EVAP canister bracket nut.

    7. Object Number: 670051 Size: SH
  7. Loosen the fuel tank fill pipe hose clamp.
  8. Disconnect the fuel tank fill pipe hose (2) from the fuel tank (1).
  9. Disconnect the EVAP vent pipe near the fill pipe hose. Refer to Plastic Collar Quick Connect Fitting Service .

    10. Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.


    Object Number: 670192 Size: SH
  10. With the aid of an assistant or a transmission jack, support the fuel tank and remove the fuel tank strap attaching bolts (2).
  11. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.

    12. Object Number: 670190 Size: SH
  12. If the fuel tank is being replaced, perform the following steps:
    13. 12.1. Remove the fuel sender (1). Refer to Fuel Tank Module Replacement .
    12.2. Remove the fuel tank wiring harness from the fuel tank.
    12.3. Remove the fuel pipes from the fuel tank.
    12.4. Remove the EVAP vent solenoid valve (2). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
    12.5. Remove the EVAP canister (3). Refer to Evaporative Emission Canister Replacement .

Installation Procedure

    Object Number: 670190 Size: SH
  1. Install the EVAP canister (3). Refer to Evaporative Emission Canister Replacement .
  2. Install the EVAP vent solenoid valve (2). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
  3. Install the fuel pipes to the fuel tank.
  4. Install the fuel tank wiring harness to the fuel tank.
  5. Install the fuel sender (1). Refer to Fuel Tank Module Replacement .

    6. Object Number: 670194 Size: SH
  6. With the aid of an assistant or a transmission jack, position and support the fuel tank.

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

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


    Object Number: 670192 Size: SH
  7. Install the fuel tank strap bolts (2).

    8. Tighten
    Tighten the fuel tank strap bolts to 47 N·m (35 lb ft).


    Object Number: 669530 Size: SH
  8. Install the EVAP canister bracket nut.

    9. Tighten
    Tighten the EVAP canister bracket nut to 6 N·m (53 lb in).

  9. Install the EVAP vent pipe near the fill pipe hose. Refer to Plastic Collar Quick Connect Fitting Service .

    10. Object Number: 670051 Size: SH
  10. Install the fuel tank filler pipe hose (2) to the fuel tank (1).

    11. Tighten
    Tighten the fuel tank filler pipe hose clamp to 2.5 N·m (22 lb in).


    Object Number: 1404183 Size: SH
  11. Connect the fuel pipes.

    12. Object Number: 680801 Size: SH
  12. Install the fuel tank wiring harness connector (1).
  13. Lower the vehicle.
  14. Add fuel as necessary and install the fuel tank filler pipe cap.
  15. Inspect for fuel leaks. Perform the following steps:
    16. 15.1. Turn ON the ignition for 2 seconds.
    15.2. Turn OFF the ignition for 10 seconds.
    15.3. Turn ON the ignition.
    15.4. Inspect for fuel leaks.