GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Aveo 🢒 Engine 🢒 Engine Controls and Fuel - 1.6L (LXV) 🢒 Fuel Tank Replacement

Removal Procedure

    Warning: Refer to Fuel Pressure Caution in the Preface section.


    Object Number: 2042503 Size: SH
  1. Relieve the fuel pressure. Refer to Fuel Pressure Relief.

    2. Warning: Refer to Battery Disconnect Warning in the Preface section.

  2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  3. Drain the fuel tank.
  4. Disconnect the parking brake cable retainer clamps (1) and the support along the fuel tank to provide clearance for the tank.

    5. Object Number: 2042504 Size: SH
  5. Remove the fuel tank filler tube clamp at the fuel tank.
  6. Disconnect the fuel tank filler tube (2) and vent tube (1).
  7. Disconnect the canister vapor tube at control valve vapor tube.

    8. Object Number: 2042505 Size: SH
  8. Disconnect the fuel pump harness connector at the right rear corner of the fuel tank.
  9. Disconnect the fuel lines (1) near the right front of the fuel tank.
  10. Disconnect the wiring harness clips and the fuel line clips as needed.

    11. Object Number: 2042506 Size: SH
  11. Support the fuel tank.
  12. Remove the fuel tank retaining bolts (1).
  13. Carefully lower the fuel tank.
  14. Remove the fuel tank.

Installation Procedure
  1. Raise the fuel tank into position.

    2. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 2042506 Size: SH
  2. Install the fuel tank mounting bolts (1).

    3. Tighten
    Tighten the fuel tank retaining bolts to 20  N·m (15 lb ft).


    Object Number: 2042505 Size: SH
  3. Connect the fuel lines (1).
  4. Connect the wiring harness clips and the fuel line clips as needed.
  5. Connect the fuel pump electrical connector.
  6. Connect the fuel vapor line.

    7. Object Number: 2042504 Size: SH
  7. Connect the fuel tank filler tube (2) and fuel tank vent tube (1).
  8. Install the fuel tank filler tube clamp at the fuel tank.

    9. Object Number: 2042503 Size: SH
  9. Install the parking brake cable retainer clamps (1) and the support.

    10. Tighten
    Tighten the parking brake cable retainer clamps to 10 N·m (89 lb in).

  10. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  11. Fill the fuel tank.
  12. Perform a leak check of the fuel tank and the fuel line connections.