GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Aztek - FWD 🢒 Engine 🢒 Engine Controls - 3.4L 🢒 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 at the body pass through (1).

    5. Object Number: 670056 Size: SH
  5. Disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter (1). Refer to Plastic Collar Quick Connect Fitting Service .
  6. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the fuel tank evaporative emission (EVAP) pipe quick-connect fitting near the fuel filter.
  8. Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer.

    9. Object Number: 669530 Size: SH
  9. Remove the retaining nut for the EVAP canister bracket.

    10. Object Number: 670051 Size: SH
  10. Loosen the fuel tank filler pipe hose clamp.
  11. Disconnect the fuel tank filler pipe (2) from the fuel tank (1).

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


    Object Number: 670192 Size: SH
  12. With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts (2).
  13. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
  14. If the fuel tank is not being replaced, go to the Installation Procedure.

    15. Object Number: 670190 Size: SH
  15. Disconnect the fuel tank wiring harness from the fuel sender assembly.
  16. Remove the fuel sender shield from the fuel tank.
  17. Disconnect the fuel feed and return pipe quick-connect fittings at the fuel sender (1). Refer to Plastic Collar Quick Connect Fitting Service .
  18. Disconnect the EVAP vapor pipe assembly from the fuel sender.
  19. Remove the fuel and/or EVAP pipe assembly from the fuel tank.
  20. Remove the fuel sender assembly (1). Refer to Fuel Sender Assembly Replacement .
  21. Remove the EVAP vent valve (2). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
  22. 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 valve (2). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
  3. Install the fuel sender assembly (1). Refer to Fuel Sender Assembly Replacement .
  4. Install the fuel and/or EVAP pipe assembly.
  5. Connect the EVAP vapor pipe to the fuel sender assembly.
  6. Connect the fuel feed and fuel return pipes at the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .

    7. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  7. Install the fuel sender shield to the fuel tank.

    8. Tighten
    Tighten the shield nuts to 6 N·m (53 lb in).

  8. Connect the fuel tank wiring harness to the fuel sender assembly.

    9. Object Number: 670194 Size: SH
  9. With the aid of an assistant, position and support the fuel tank.

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


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

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


    Object Number: 669530 Size: SH
  11. Install the EVAP canister retaining nut.

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


    Object Number: 670051 Size: SH
  12. Connect the fuel tank filler pipe (2) to the fuel tank (1).

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


    Object Number: 670056 Size: SH
  13. Connect the fuel feed pipe quick-connect fitting (1) at the inlet side of the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the fuel return pipe quick-connect fitting near the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  15. Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.

    16. Object Number: 680801 Size: SH
  16. Connect the fuel tank wiring harness connector (1) at the body pass-through.
  17. Lower the vehicle.
  18. Add fuel and reinstall the fuel tank filler pipe cap.
  19. Connect the negative battery cable.
  20. Inspect for fuel leaks with the following procedure:
    21. 20.1. Turn ON the ignition for 2 seconds.
    20.2. Turn OFF the ignition for 10 seconds.
    20.3. Turn ON the ignition.
    20.4. Inspect for fuel leaks.