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

Removal Procedure

    Object Number: 1263839 Size: SH

    Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel pressure regulator or the fuel pressure gage may result.

    Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Relieve the test 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 from the fuel tank.
  4. Remove the parking brake cable retaining bracket bolts/nuts.

    5. Object Number: 1263840 Size: SH
  5. Disconnect the fuel tank filter tube from the fuel tank.
  6. Disconnect the fuel tank vent tube from the fuel tank.
  7. Disconnect the wiring harness straps from the fuel tank.
  8. Disconnect the fuel pump harness.

    9. Object Number: 1263841 Size: SH
  9. Disconnect the fuel inlet line.
  10. Disconnect the fuel return line.
  11. Disconnect the fuel CCP line.

    12. Object Number: 1263842 Size: SH
  12. Support the fuel tank.
  13. Remove the fuel tank strap retaining bolts.
  14. Remove the tank straps.

    15. Notice: Use extreme care when lowering the fuel tank. The fuel sender is made of plastic. Lowering the fuel tank may damage the fuel sender.

  15. Carefully lower the fuel tank.
  16. Remove the fuel tank.
  17. Transfer any parts as needed.

Installation Procedure

    Object Number: 1263842 Size: SH
  1. Raise the fuel tank.
  2. Install the fuel tank straps.

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

    Notice: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.

  3. Install the fuel tank straps.

    4. Tighten
    Tighten the fuel tank strap retaining bolts to 13 N·m (115 lb in).


    Object Number: 1263841 Size: SH
  4. Connect the fuel CCP line.
  5. Connect the fuel return line.
  6. Connect the fuel inlet line.

    7. Object Number: 1263840 Size: SH
  7. Connect the fuel pump harness connector.
  8. Connect the wiring harness strap to the fuel tank.
  9. Connect the fuel tank vent tube to the fuel tank.
  10. Connect the fuel tank filter tube to the fuel tank.

    11. Object Number: 1263839 Size: SH
  11. Install the parking brake cable retaining bracket bolt/nuts.

    12. Tighten
    Tighten the parking brake cable retaining bracket bolt/nuts to 10 N·m (89 lb in).

  12. Connect the negative battery cable.
  13. Fill the fuel tank.
  14. Perform a leak check of the fuel tank and the fuel line connections.