GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2001 🢒 Regal (China) 🢒 Engine 🢒 Engine Controls - 2.5L (LB8) and 3.0L (LW9) 🢒 Fuel Tank Replacement

Removal Procedure

Caution: In order to reduce the risk of fire and personal injury observe the following items:

   • Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes
   • Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak.
   • Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.
   • Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. 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.)

Caution: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

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 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 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. Disconnect the fuel tank filler hose from the fuel tank.

    6. Object Number: 32401 Size: SH
  6. Disconnect the fuel tank fuel pipes from the chassis fuel return pipe and in-line fuel filter. Refer to Metal Collar Quick Connect Fitting Service .
  7. Disconnect the fuel tank purge pipe from the chassis purge pipe.

    8. Object Number: 727165 Size: SH
  8. Disconnect the EVAP hoses/pipes (2) from the EVAP canister (1).
  9. Release the EVAP pipes retainer from the underbody bar.
  10. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.

    11. Object Number: 32215 Size: SH
  11. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts.
  12. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
  13. If the fuel tank is not being replaced, refer to the fuel tank installation procedure.

    14. Object Number: 727162 Size: SH
  14. Disconnect the fuel feed and return pipes (2 and 4) from the fuel sender assembly (1).
  15. Disconnect the EVAP pipe (3) from the fuel sender assembly (1).
  16. Remove the fuel tank fuel bundle.

    17. Object Number: 12743 Size: SH
  17. 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. Object Number: 727162 Size: SH
  2. Connect the fuel feed and return pipes (2 and 4) to the fuel sender assembly (1).
  3. Connect the EVAP pipe (3) to the fuel sender assembly (1).

    4. Object Number: 32215 Size: SH
  4. With the aid of an assistant, position and support the fuel tank.

    5. Notice: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.

  5. Install the fuel tank retaining strap attaching bolts (2).

    6. Tighten
    Tighten the front fuel tank retaining strap bolts (2) to 47 N·m (35 lb ft).

  6. Install the rubber exhaust pipe hangers in order to aline the exhaust system.
  7. Press the EVAP pipes retainer into the underbody bar.

    8. Object Number: 727165 Size: SH
  8. Connect the EVAP hoses/pipes (2) at the EVAP canister (1).

    9. Object Number: 32401 Size: SH
  9. Connect the fuel tank fuel pipes to the chassis fuel return pipe and in-line fuel filter. Refer to Metal Collar Quick Connect Fitting Service .
  10. Connect the fuel tank purge pipe to the chassis purge pipe.

    11. Object Number: 155468 Size: SH
  11. Connect the fuel tank filler hose to the fuel tank.

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

    14. Tighten
    Tighten the fuel tank filler pipe hose clamp to 2.5 N·m (22  lb in).

  14. Inspect the fuel and EVAP pipes making sure they were not kinked or damaged during removal and installation.
  15. Lower the vehicle.
  16. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  17. Add fuel and install the fuel tank filler pipe cap.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  19. Inspect for fuel leaks.
    20. 19.1. Turn ON the ignition for 2 seconds.
    19.2. Turn OFF the ignition for 10 seconds.
    19.3. Turn ON the ignition.
    19.4. Inspect for fuel leaks.