GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Grand Prix 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 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.

Notice: Do not bend the fuel tank straps as this may damage the straps.

Notice: 

   • Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle.
   • Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes.
   • Replace the vapor pipes with original equipment or parts that meet GM specifications.
   • Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the hose.

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

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

  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    4. Object Number: 186674 Size: SH
  4. Loosen the fuel tank filler hose clamp (1) at the fuel tank (3).

    5. Object Number: 155468 Size: SH
  5. Remove the fuel tank filler hose from the fuel tank.

    6. Object Number: 32401 Size: SH
  6. Disconnect the quick-connect fittings at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the evaporative emission (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. Object Number: 32215 Size: SH
  9. Support the fuel tank with a suitable jack.
  10. Support the fuel tank strap bolts.
  11. Lower the fuel tank to access the EVAP connections.

    12. Object Number: 230780 Size: SH
  12. Disconnect the EVAP pipes (4) from the rear of the fuel tank.
  13. Disconnect the EVAP pipe (2) from the fuel limiter vent valve.
  14. Disconnect the fuel filler neck EVAP pipe (3) at the rear of the fuel tank.
  15. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.

    16. Object Number: 32153 Size: SH
  16. Remove the fuel feed, fuel return, EVAP pipe assemblies and the insulator clips from the fuel tank.
  17. Remove the EVAP canister from the fuel tank.

    18. Object Number: 12743 Size: SH
  18. 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 EVAP canister to the fuel tank.

    3. Object Number: 32153 Size: SH
  3. Connect the fuel feed, fuel return, EVAP pipe assemblies and install the insulator clips.

    4. Object Number: 32215 Size: SH
  4. Install the fuel tank to a suitable jack.

    5. Object Number: 230780 Size: SH
  5. Connect the EVAP pipes (4) to the rear of the fuel tank.
  6. Connect the EVAP pipe (2) to the fuel limiter vent valve.
  7. Connect the fuel filler EVAP pipe (3) at the rear of the fuel tank.
  8. Raise the fuel tank to the original position.

    9. 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.

  9. Install the fuel tank retaining strap bolts.

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

  10. Remove the jack from the fuel tank.

    11. Object Number: 32401 Size: SH
  11. Connect the quick-connect fittings at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Connect the EVAP pipe at the front of the fuel tank.

    13. Object Number: 155468 Size: SH
  13. Install the fuel tank filler hose to the fuel tank.

    14. Object Number: 186674 Size: SH
  14. Inspect and make sure that the filler hose (4) is fully seated on fuel tank port (2).
  15. Make sure the clamp (1) is properly located on tank port between the bead (5) and the tank (3).

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

  16. Install the exhaust pipe to the exhaust hangers.
  17. Inspect the fuel and EVAP pipes making sure they were not kinked or damaged during removal and installation.
  18. Lower the vehicle.
  19. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  20. Add fuel and install the fuel fill cap.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical
  22. Inspect for leaks.
    23. 22.1. Turn ON the ignition for 2 seconds.
    22.2. Turn OFF the ignition for 10 seconds.
    22.3. Turn ON the ignition.
    22.4. Inspect for fuel leaks.
  23. Install fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.