GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1999 🢒 Sunfire 🢒 Engine 🢒 Engine Controls - 2.4L 🢒 Fuel Tank Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the fuel tank. Refer to Fuel Tank Draining .

    3. Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

  3. Raise the vehicle and suitably support.

    4. Object Number: 54522 Size: SH
  4. Grasp the nylon fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for the other nylon fuel pipe quick-connect fitting.

    5. Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

  5. Using compressed air, blow out dirt from the quick-connect fittings at end of the fuel pipes.

    6. Object Number: 54520 Size: SH
  6. Disconnect the quick-connect fitting at the fuel filter.
  7. Remove the quick connect fittings at the end of the fuel pipe and vapor pipes. Refer to Metal Collar Quick Connect Fitting Service .
  8. Remove the muffler support bolts.
  9. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear suspension.
  10. Remove the heat shield.
  11. Remove the hoses at tank from filler, vent and vapor pipes.

    12. Object Number: 49897 Size: SH
  12. With the aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps.

    13. Object Number: 373185 Size: SH
  13. With the aid of an assistant, lower the fuel tank.
  14. Remove the fuel tank pressure sensor electrical connector.
  15. Remove the fuel sender electrical connector.
  16. Remove the tank from the vehicle.
  17. Remove the fuel sender assembly from the tank. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Important: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel pipe O-rings for cuts, nicks, swelling or distortion. Replace if necessary.

  1. Install the fuel sender assembly to tank. Refer to Fuel Sender Assembly Replacement .

    2. Object Number: 49897 Size: SH
  2. With the aid of an assistant, raise the fuel tank (1) to body.

    3. 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.

  3. Install the fuel tank retaining straps.

    4. Tighten
    Tighten the bolts to 35 N·m (26 lb ft)


    Object Number: 373185 Size: SH
  4. Install the fuel tank pressure sensor electrical connector.
  5. Install the fuel tank sender electrical connector.
  6. Install the hoses to filler, vent and vapor pipes
  7. Install the heat shield.
  8. Install the exhaust rubber hangers.

    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 muffler support bolts.

    10. Tighten
    Tighten the bolt to 15 N·m (11 lb ft).

    Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

  10. Install the nylon fuel pipe and fuel filter quick-connect fittings. Refer to Metal Collar Quick Connect Fitting Service .
  11. Lower the vehicle.
  12. Refill the tank.
  13. Connect the negative battery cable.
  14. Inspect for fuel leaks through the following steps:
    15. 14.1. Turn the ignition switch to the ON position for two seconds
    14.2. Turn the ignition switch to the OFF position for ten seconds.
    14.3. Turn the ignition switch to the ON position
    14.4. Check for fuel leaks.