GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Firebird 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 21288 Size: SH
  1. Relieve the fuel system pressure. Refer to the 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. Remove the fuel fill pipe shield.

    5. Object Number: 327608 Size: SH
  5. Remove the fuel tank fill pipe support bracket bolt.
  6. Remove the exhaust system from the catalytic converter back. Refer to Muffler Replacement in Engine Exhaust.
  7. Remove the exhaust pipe heat shield and the exhaust muffler heat shield. Refer to Muffler Replacement in Engine Exhaust.

    8. Object Number: 356450 Size: SH
  8. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  9. Disconnect the fuel return pipe (2) at the rear quick-connect fitting.
  10. Disconnect the evaporative emission (EVAP) purge pipe (1) at the rear quick-connect fitting.

    11. Object Number: 327204 Size: SH
  11. Disconnect the fuel feed pipe at the fuel filter inlet.
  12. Cap the fuel pipes in order to prevent possible fuel system contamination.

    13. Object Number: 355809 Size: SH
  13. Remove the rear pipe clip.

    14. Object Number: 327609 Size: SH
  14. Remove the fuel tank.
  15. Place the fuel tank in a suitable work area.

    16. Object Number: 376991 Size: SH
  16. Disconnect the hose from the EVAP canister vent valve.
  17. Remove the EVAP canister vent valve from the fuel tank bracket.

    18. Object Number: 376984 Size: SH
  18. Disconnect the fill limiter vent valve pipe from the EVAP canister.
  19. Carefully bend the fuel tank bracket in order to remove the EVAP canister.

    20. Object Number: 376978 Size: SH
  20. Disconnect the fuel feed pipe (4), the fuel return pipe (2), and the EVAP pipe (3) from the fuel sender.
  21. Disconnect the EVAP pipe from the fill limiter vent valve pipe (10).
  22. Remove the fuel and EVAP pipes from the fuel tank.
  23. Disconnect the fuel sender electrical connectors (1).
  24. Remove the fuel sender electrical harness (8) from the fuel tank.

    25. Object Number: 376982 Size: SH
  25. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .

    26. Object Number: 376980 Size: SH
  26. Remove the fuel fill hose to fuel tank clamp (1).
  27. Remove the fuel fill pipe and hose from the fuel tank.

Installation Procedure

    Object Number: 376980 Size: SH
  1. Install the fuel fill pipe and hose to the fuel tank.

    2. 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.

    Tighten
    Tighten the fuel fill hose clamp (1) to 2.5 N·m (22 lb in).


    Object Number: 376982 Size: SH
  2. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .

    3. Object Number: 376978 Size: SH
  3. Install the fuel sender electrical harness (8) to the fuel tank.
  4. Connect the fuel level sensor electrical connectors (1).
  5. Install the fuel feed pipe (4) and the fuel return pipe (2) to the fuel sender and the fuel tank clips.
  6. Connect the EVAP pipe (3) to the fuel sender.
  7. Connect the EVAP pipe to the fill limiter vent valve pipe (10).

    8. Object Number: 376984 Size: SH
  8. Carefully bend the fuel tank bracket in order to install the EVAP canister.
  9. Connect the fill limiter vent valve pipe to the EVAP canister.

    10. Object Number: 376991 Size: SH
  10. Install the EVAP canister vent valve to the fuel tank bracket.
  11. Connect the hose to the EVAP canister vent valve.

    12. Object Number: 327611 Size: SH
  12. With the aid of an assistant, position and support the fuel tank.
  13. Position the fuel tank straps up.
  14. Install the fuel tank strap attaching bolts.

    15. Tighten
    Tighten the fuel tank strap attaching bolts to 45 N·m (33 lb ft).


    Object Number: 327144 Size: SH
  15. Connect the fuel level sensor and the fuel pressure sensor electrical connectors at the pass through connector.

    16. Object Number: 327204 Size: SH
  16. Remove the caps from the fuel pipes.
  17. Connect the fuel feed pipe at the fuel filter inlet.

    18. Object Number: 356450 Size: SH
  18. Connect the EVAP purge pipe (1) at the rear quick-connect fitting.
  19. Connect the fuel return pipe (2) at the rear quick-connect fitting.

    20. Object Number: 355809 Size: SH
  20. Install the fuel and EVAP pipes into the pipe clip.
  21. Align the fuel and EVAP pipes into a flat position.
  22. Install the pipe clip bolt.

    23. Tighten
    Tighten the pipe clip bolt to 5.5 N·m (49 lb in).


    Object Number: 327608 Size: SH
  23. Install the fuel tank fill pipe support bracket bolt.

    24. Tighten
    Tighten the fuel tank fill pipe support bracket bolt to 10 N·m (89 lb in).

  24. Install the exhaust system heat shields and attaching screws. Refer to Muffler Replacement in Engine Exhaust.
  25. Install the exhaust system. Refer to Muffler Replacement in Engine Exhaust.

    26. Object Number: 21288 Size: SH
  26. Install the fuel filler pipe shield.
  27. Lower the vehicle.
  28. Refill the fuel tank.
  29. Install the fuel filler cap.
  30. Connect the negative battery cable.
  31. Inspect for leaks.
    32. 31.1. Turn ON the ignition for 2 seconds.
    31.2. Turn OFF the ignition for 10 seconds.
    31.3. Turn ON the ignition .
    31.4. Check for fuel leaks.