GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Lumina 🢒 Engine 🢒 Engine Controls - 3.4L (VIN X) 🢒 Fuel Tank Replacement

Removal Procedure

Caution: Provide additional support when a vehicle is on a hoist:

   • Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
   • Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

Important: Important do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.


    Object Number: 12742 Size: SH
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief W 3800, Fuel Pressure Relief W 3100, Fuel Pressure Relief W 3.4L.
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure W 3800, Fuel Tank Draining W 3100, Fuel Tank Draining Procedure W 3.4L.
  3. Raise the vehicle.
  4. Remove the fuel tank filler EVAP hose from the fuel tank.
  5. Remove the fuel tank filler hose from the fuel tank.
  6. Remove the quick-connect fittings at the fuel tank. Refer to Servicing Quick Connect Fittings W 3800, Servicing Quick Connect Fittings W 3100, Servicing Quick Connect Fittings W 3.4L.
  7. Remove the 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. Remove the exhaust pipe heat shield bolts and the exhaust pipe heat shield.

    10. Object Number: 12739 Size: SH
  10. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.
  11. Lower the fuel tank enough in order to disconnect the fuel sender electrical connector and remove the fuel sender retaining clips.
  12. Remove the EVAP pipe to the rear of the fuel tank.
  13. Remove the EVAP pipe to the fuel sender assembly.
  14. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
  15. If the fuel tank is not being replaced, go to Install or Connect.
  16. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement W 3800, Fuel Sender Assembly Replacement W 3100, Fuel Sender Assembly Replacement W 3.4L.
  17. Remove the retaining clip from the EVAP pipe. Note the position of the retaining clip for installation.
  18. Remove the EVAP pipe from the insulator clips. Note the position of the EVAP pipe for installation.
  19. Remove the quick-connect fittings at the fuel sender. Refer to Servicing Quick Connect Fittings W 3800, Servicing Quick Connect Fittings W 3100, Servicing Quick Connect Fittings W 3.4L.
  20. Remove the fuel feed and fuel return pipe assemblies and the insulator clips from the fuel tank.

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

Installation Procedure

    Object Number: 12743 Size: SH
  1. Install the insulator pads on the fuel tank.
  2. Install the insulator clips.
  3. Install the quick-connect fittings at the fuel sender. Refer to Servicing Quick Connect Fittings W 3800, Servicing Quick Connect Fittings W 3100, Servicing Quick Connect Fittings W 3.4L.
  4. Install the fuel feed and fuel return pipe assemblies.
  5. Position the EVAP pipe on the insulator clips as noted during disassembly.
  6. Install the retaining clip on the EVAP pipe.
  7. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement W 3800, Fuel Sender Assembly Replacement W 3100, Fuel Sender Assembly Replacement W 3.4L.

    8. Object Number: 12739 Size: SH
  8. With the aid of an assistant, position and support the fuel tank.
  9. Install the EVAP pipe to the rear of the fuel tank.
  10. Install the EVAP pipe to the fuel sender assembly.
  11. Install the fuel sender electrical connector and the fuel sender retaining clips.
  12. Install the fuel tank retaining strap attaching bolts (4).

    13. Tighten
    Tighten the front and rear fuel tank retaining strap bolts (4) to 47 N·m(35  lb. ft.).

  13. Install the quick-connect fittings. Refer to Servicing Quick Connect Fittings W 3800, Servicing Quick Connect Fittings W 3100, Servicing Quick Connect Fittings W 3.4L.
  14. Install the EVAP pipe at the front of the fuel tank.

    15. Object Number: 12742 Size: SH
  15. Install the fuel tank filler EVAP pipe to the fuel tank.

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

  16. Install the fuel tank filler pipe to the fuel tank.

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

  17. Install the heat shield and the heat shield attaching screws.
  18. Install the rubber exhaust pipe hangers.
  19. Lower the vehicle.
  20. Add fuel and install the fuel tank filler pipe cap.
  21. Install the negative battery cable.
  22. Inspect for leaks.
    23. 22.1. Inspect turn the ignition switch to the ON position for two seconds.
    22.2. Turn the ignition switch to the OFF for ten seconds.
    22.3. Turn the ignition switch to the ON position again.
    22.4. Check for fuel leaks