GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2006 🢒 Vibe - AWD 🢒 Engine 🢒 Engine Controls - 1.8L (LNK) 🢒 Fuel Tank Replacement

Removal Procedure

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

   • 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: The fuel tank equipped with ORVR components require special handling. Follow all instructions for servicing the fuel tank as specified in the service procedures. Damage to the fuel system components and the failure to meet the Federal Regulations may result from incorrect servicing of the fuel tank.


    Object Number: 850572 Size: SH
  1. Drain the fuel tank. Refer to Fuel Tank Draining .
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the catalytic converter and intermediate pipe assembly from the vehicle. Refer to Catalytic Converter Replacement in Engine Exhaust.
  4. Remove the 2 left side bolts (1) and the 3 right side bolts (3) from the rear exhaust heat shield (2).
  5. Remove the rear exhaust heat shield (2) from the underbody.

    6. Object Number: 853035 Size: SH
  6. Remove the 2 bolts (1) securing the parking brake cable (2) on the right side of the vehicle.

    7. Object Number: 853058 Size: SH
  7. Disconnect the fuel supply line. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the fuel tank vapor line with the quick release fitting from the fuel vapor pipe. Refer to Plastic Collar Quick Connect Fitting Service .

    9. Object Number: 853047 Size: SH
  9. Loosen the fuel filler hose clamp (1).
  10. Disconnect the fuel filler hose (2) from the fuel tank.
  11. Disconnect the on-board refueling vapor recovery (ORVR) vent line from the fill limiter vent valve (FLVV) of the evaporative emission (EVAP) canister. Refer to Plastic Collar Quick Connect Fitting Service .

    12. Object Number: 853034 Size: SH
  12. Remove the 4 bolts (1) and the 2 fuel tank straps (2) from the vehicle.
  13. Remove the fuel tank (3) from the vehicle.

    14. If replacing the fuel tank, remove all lines and hoses, and install on the replacement fuel tank.

Installation Procedure


    Object Number: 853034 Size: SH
  1. Install the fuel tank (3) to the vehicle.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the 2 fuel tank straps (2) to the vehicle with the 4 bolts (1).

    3. Tighten
    Tighten the bolts to 39 N·m (29 lb ft).


    Object Number: 853047 Size: SH
  3. Connect the fuel filler hose (2) to the fuel tank.
  4. Secure the fuel filler hose (2) to the fuel tank with the hose clamp (1).

    5. Object Number: 853058 Size: SH
  5. Connect the fuel supply line. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Connect the fuel tank vapor line with the quick release fitting to the fuel vapor pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Connect the ORVR vent line to the FLVV on the EVAP canister.

    8. Object Number: 853035 Size: SH
  8. Secure the parking brake cable (2) on the right side of the vehicle with 2 bolts (1).

    9. Tighten
    Tighten the bolts to 5.4 N·m (48 lb in).


    Object Number: 850572 Size: SH
  9. Install the rear exhaust heat shield (2) to the vehicle underbody.
  10. Secure the rear exhaust heat shield (2) with the 2 left side bolts (1) and the 3 right side bolts (3).

    11. Tighten
    Tighten the bolts to 5.4 N·m (48 lb in).

  11. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle. Refer to Catalytic Converter Replacement in Engine Exhaust.
  12. Lower the vehicle.
  13. If the fuel sender assembly was removed, refer to Fuel Sender Assembly Replacement .

    14. Object Number: 1460719 Size: SH
  14. Connect the ORVR vent line (2) to the fuel sender assembly (1).
  15. Slide the

    16. Object Number: 1465470 Size: SH
  16. Slide the quick connect clasp (1) into the lock position on the ORVR vent line (2).

    17. Object Number: 1460705 Size: SH
  17. Connect the fuel supply line (1) to the fuel sender assembly.

    18. Object Number: 1465471 Size: SH
  18. Secure the fuel supply line (2) to the sender assembly with the retaining clip (1).

    19. Object Number: 1460703 Size: SH
  19. Connect the fuel sender electrical connector (2) to the fuel sender assembly.
  20. Add fuel to the fuel tank.
  21. Connect the negative battery cable.

    22. Tighten
    Tighten the retainer for the negative battery cable terminal to 15 N·m (11 lb ft).

  22. Pressurize the fuel system and check for leaks.
  23. Install the access panel (1) to the rear seat floor panel (3).
  24. Secure the access panel to the body with 4 bolts.

    25. Tighten
    Tighten the 4 bolts to 6 N·m (53 lb in).

  25. Relocate the carpet under the ride side seat area and the right sill plate area.
  26. Install the sill plate to the right side door opening .

    27. Object Number: 1464194 Size: SH
  27. Lower the rear seat bottom cushion (1) and secure with 2 bolts (2).

    28. Tighten
    Tighten the 2 bolts to 41 N·m (30 lb ft).