GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2006 🢒 Grand Prix 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Fuel Tank Replacement

Removal Procedure

    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: Always maintain cleanliness when servicing the 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 and support the vehicle. Refer to Lifting and Jacking the Vehicle .

    4. Object Number: 186674 Size: SH
  4. Loosen the fuel 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: 911091 Size: SH
  6. Disconnect the fuel feed (4), the fuel return (2) and the evaporative emission (EVAP) (3) pipes at the fuel filter area. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Support the exhaust system.
  8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.

    9. Object Number: 698635 Size: SH
  9. Separate the two halves of the EVAP fresh air hose at the splice.

    10. Object Number: 699555 Size: SH
  10. Remove the fuel tank shield push pins (2).
  11. Remove the fuel tank shield (3).

    12. Object Number: 699556 Size: SH

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

  12. Support the fuel tank with a suitable jack.
  13. Remove the fuel tank strap bolts (2).
  14. Using the suitable jack lower the fuel tank.
  15. Disconnect the fuel sender assembly electrical connectors.
  16. Remove the fuel tank and place the tank in a suitable work area.

    17. Object Number: 911093 Size: SH

    Important: Note the routing of the pipe assemblies and the retaining clips for installation.

  17. Disconnect and remove the fuel feed (6), the fuel return (7), and the EVAP pipe (5) assemblies and the insulator clips from the fuel tank (1). Refer to Plastic Collar Quick Connect Fitting Service .
  18. Remove the EVAP canister (2) from the fuel tank (1).
  19. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.

Installation Procedure

    Object Number: 911093 Size: SH
  1. Install the insulator pads to the fuel tank.
  2. Install the EVAP canister (2) to the fuel tank (1).

    3. 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.

  3. Install and connect the fuel feed (6), the fuel return (7), and the EVAP pipe (5) assemblies and the insulator clips to the fuel tank (1) as noted during removal. Refer to Plastic Collar Quick Connect Fitting Service .

    4. Object Number: 699556 Size: SH
  4. Install the fuel tank to a suitable jack.
  5. Raise the fuel tank (1) to the original position.

    6. 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.

  6. Install the fuel tank strap bolts (2).

    7. Tighten
    Tighten the bolts to 48 N·m (35 lb ft).

  7. Remove the jack from the fuel tank.

    8. Object Number: 699555 Size: SH
  8. Position the fuel tank shield (3) to the fuel tank (1).
  9. Install the push pins (2).

    10. Object Number: 698635 Size: SH
  10. Install the two parts of the EVAP fresh air hose at the splice.
  11. Raise the exhaust system to the original position.
  12. Install the exhaust system to the exhaust pipe hangers.

    13. Object Number: 911091 Size: SH
  13. Connect the fuel feed (4), the fuel return (2) and the evaporative emission (EVAP) (3) pipes at the fuel filter area. Refer to Plastic Collar Quick Connect Fitting Service .

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

    15. Object Number: 186674 Size: SH
  15. Fully seat the filler hose (4) on the fuel tank port (2).
  16. Ensure that the clamp (1) is properly located on the tank port between the bead (5) and the tank (3).

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

  17. Lower the vehicle.
  18. Add fuel and install the fuel fill cap.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  20. Inspect the fuel system for leaks by performing the following steps:
    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.
  21. Install fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .