GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 Engine 🢒 Engine Controls - 1.6L (L91) 🢒 Fuel Tank Replacement

Removal Procedure

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


    Object Number: 1289366 Size: SH
  1. Relieve the fuel pressure. Refer to Fuel Pressure Relief .

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

  2. Disconnect the negative battery cable.
  3. Drain the fuel tank.
  4. Remove the front muffler. Refer to Muffler Replacement in Engine Exhaust.

    5. Object Number: 1289367 Size: SH
  5. Remove the fuel tank filler tube clamp at the fuel tank.
  6. Disconnect the fuel tank filler tube.
  7. Disconnect the fuel vapor line near the fuel tank filler tube.
  8. Disconnect the fuel pump harness connector.

    9. Object Number: 1289369 Size: SH
  9. Disconnect the fuel inlet line and the fuel return line near the right front of the fuel tank.
  10. Remove the fuel pump. Refer to Fuel Pump Replacement .

    11. Object Number: 1289371 Size: SH
  11. Remove the parking brake cables support brackets.
  12. Support the fuel tank.
  13. Remove the fuel tank strap retaining nuts.
  14. Remove the fuel tank strap.
  15. Carefully lower the fuel tank.
  16. Remove the fuel tank.
  17. Transfer any parts as needed.

Installation Procedure

    Object Number: 1289371 Size: SH
  1. Raise the fuel tank into position.
  2. Install the fuel tank straps.

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

  3. Install the fuel tank strap retaining nuts.

    4. Tighten
    Tighten the fuel tank strap retaining nuts to 20 N·m (15 lb ft).

  4. Install the parking brake cables support bracket.

    5. Object Number: 1289369 Size: SH
  5. Install the fuel pump. Refer to Fuel Pump Replacement .
  6. Connect the fuel outlet line and the fuel return line.

    7. Object Number: 1289367 Size: SH
  7. Connect the fuel pump harness connector.
  8. Connect the fuel vapor line.
  9. Connect the fuel tank filler tube.
  10. Connect the fuel tank vent tube.
  11. Install the fuel tank filler tube clamp at the fuel tank.

    12. Object Number: 1289366 Size: SH
  12. Install the front muffler. Refer to Muffler Replacement in Engine Exhaust.
  13. Connect the negative battery cable.
  14. Fill the fuel tank.
  15. Perform a leak check of the fuel tank and the fuel line connections.