GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2009 🢒 G8 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Fuel Tank Replacement

Special Tools
    • EN-46843
    • 7370
    • 7371
    • EN-48536

Removal Procedure
  1. Ignition OFF.

    2. Warning: Refer to Battery Disconnect Warning in the Preface section.

  2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.

    3. Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section.

  3. Drain the fuel tank into a suitable container. Refer to Fuel Tank Draining.

    4. Warning: Refer to Safety Glasses Warning in the Preface section.

    Danger: 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.

  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  5. Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation.
  6. Remove the exhaust system for access. Refer to Exhaust System Replacement.
  7. Remove the propeller shaft. Refer to Propeller Shaft Replacement.
  8. Remove the park brake cables. Refer to Parking Brake Rear Cable Replacement.

    9. Object Number: 2193199 Size: SH
  9. Disconnect the lower evaporative emission (EVAP) line (1) from the upper EVAP line (2). Refer to Plastic Collar Quick Connect Fitting Service.
  10. Remove the retaining hose clamp (3) from the fuel filler hose (4).
  11. Remove the retaining hose clamp (5) from the fuel filler hose (4).
  12. Remove the fuel filler hose (4) from the vehicle.

    13. Object Number: 1949815 Size: SH
  13. Disconnect the fuel feed line (1) using 7371
  14. Disconnect the EVAP line (2). Refer to Plastic Collar Quick Connect Fitting Service.

    15. Object Number: 2084586 Size: SH
  15. Disconnect the fuel tank electrical connector (1) from the chassis electrical harness.

    16. Object Number: 2172065 Size: SH
  16. Support the rear frame assembly (1) using a suitable tool (2).

    17. Object Number: 1949819 Size: SH
  17. Remove the rear frame to chassis retaining bolts (1) and discard.
  18. Remove the rear frame to chassis retaining bolts (2) and discard.

    19. Object Number: 2178933 Size: SH

    Note: Make sure that the bolts (2) extends 50mm (2 in) from the rear frame.

  19. Install the bolts (2) of EN-48536 to the rear frame mounts (1).

    20. Note: When lowering the rear frame do not to damage the rear brake hoses.

  20. Lower the rear frame onto the bolts (2) of EN-48536 .

    21. Object Number: 2193200 Size: SH
  21. Detach the EVAP canister hose connector (2) from the EVAP canister (4). Refer to Plastic Collar Quick Connect Fitting Service.

    22. Note: Squeezes the collar of the EVAP canister hose connector (3) to release the connector.

  22. Detach the EVAP canister hose connector (3) from the EVAP canister (4).
  23. Disconnect the electrical connector (1) from the EVAP canister vent solenoid (5).

    24. Object Number: 2193196 Size: SH

    Note: Take care not to damage the following components when lowering the fuel tank assembly.

       • The fuel tank assembly wiring harness.
       • The fuel feed pipe.
       • The EVAP pipes.

    Note: Support the fuel tank assembly with a suitable tool before removing the fuel tank assembly straps to chassis retaining bolts (1)

  24. Remove the fuel tank strap to chassis retaining bolts (1).
  25. With the aid of an assistant, carefully manoeuvre the fuel tank assembly from the vehicle.
  26. Remove the following components if replacing the fuel tank:
    27. • The primary fuel tank module--Refer to Primary Fuel Tank Module Replacement.
    • The secondary fuel tank module--Refer to Secondary Fuel Tank Module Replacement.
    • The fuel tank pressure sensor. Refer to Fuel Tank Pressure Sensor Replacement.
    • The fuel tank assembly electrical harness.
    • The fuel tank EVAP pipes.

Installation Procedure
  1. If the fuel tank was replaced, install the following components:
    2. • The primary fuel tank module--Refer to Primary Fuel Tank Module Replacement.
    • The secondary fuel tank module--Refer to Secondary Fuel Tank Module Replacement.
    • The fuel tank pressure sensor. Refer to Fuel Tank Pressure Sensor Replacement.
    • The fuel tank assembly electrical harness.
    • The fuel tank EVAP pipes.

    Object Number: 2193196 Size: SH

    Note: Take care not to damage the following components when installing the fuel tank assembly to the vehicle:

       • The fuel tank assembly wiring harness.
       • The fuel feed pipe.
       • The Evap pipes.

    Note: Support the fuel tank assembly with a suitable tool while installing the fuel tank assembly straps to chassis retaining bolts (1).

  2. With the aid of an assistant, carefully manoeuvre and install the fuel tank assembly to the vehicle.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the fuel tank assembly strap to chassis retaining bolts (1) and tighten to 20 N·m (15 lb ft).

    4. Object Number: 2193200 Size: SH

    Note: Listen for an audible click to confirm correct installation.

  4. Connect the electrical connector (1) to the EVAP emission canister vent solenoid (5).
  5. Attach the EVAP canister hose connector (2) to the EVAP canister (4). Refer to Plastic Collar Quick Connect Fitting Service.
  6. Attach the EVAP canister hose connector (3) to the EVAP canister (4).

    7. Object Number: 2172065 Size: SH
  7. Raise and support the rear frame assembly (1) into its position using a suitable tool (2).

    8. Object Number: 2178933 Size: SH
  8. Remove the bolts (2) of EN-48536 from the rear frame mounts (1).

    9. Object Number: 1949819 Size: SH

    Note: Using a suitable tool clean the threaded holes of the rear frame to chassis retaining bolts.

  9. Install the NEW rear frame to chassis retaining bolts (2).

    10. Do not fully tighten at this stage.

  10. Install the NEW rear frame to chassis retaining bolts (1).

    11. Do not fully tighten at this stage.

  11. Tighten the NEW rear frame to chassis retaining bolts (1) and (2) to:

    12. First Pass
    Tighten the bolts to 65 N·m (48 lb ft).

    Final Pass
    Tighten the bolts a further 125 degrees.


    Object Number: 2084586 Size: SH
  12. Connect the fuel tank assembly electrical connector (1) to the chassis electrical harness.

    13. Object Number: 1949815 Size: SH

    Note: Listen for an audible click to confirm correct installation.

  13. Connect the EVAP line (2) to the EVAP chassis pipe. Refer to Plastic Collar Quick Connect Fitting Service.
  14. Connect the fuel feed line (1) to the chassis fuel feed pipe.

    15. Object Number: 2193199 Size: SH
  15. Install the fuel filler hose (4) to the vehicle.
  16. Install the retaining hose clamp (3) to the fuel filler hose (4) and tighten to 4 N·m (35 lb in).
  17. Install the retaining hose clamp (5) to the fuel filler hose (4) and tighten to 4 N·m (35 lb in).
  18. Connect the lower EVAP line (1) to the upper EVAP line (2). Refer to Plastic Collar Quick Connect Fitting Service.
  19. Install the park brake cables. Refer to Parking Brake Rear Cable Replacement.
  20. Install the propeller shaft. Refer to Propeller Shaft Replacement.
  21. Install the exhaust system. Refer to Exhaust System Replacement.
  22. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation.
  23. Lower the vehicle to the ground.
  24. Fill the fuel tank with the drained fuel.
  25. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  26. Inspect for fuel leaks using the following procedure:
    27. • Turn ON the ignition, with the engine OFF for 2 seconds.
    • Turn OFF the ignition, for 10 seconds.
    • Turn ON the ignition, with the engine OFF.
    • Inspect for leaks.