GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Sunfire 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Fuel Tank Replacement

Removal Procedure
  1. Relieve the fuel system 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: 54520 Size: SH
  4. Disconnect the quick-connect fitting at the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Disconnect the fuel return pipe quick connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Remove the rubber exhaust hangers. Allow the exhaust system to rest on the rear axle.
  7. Remove the exhaust heat shield.
  8. Loosen the fuel filler hose clamp at the fuel tank.
  9. Disconnect the fuel filler hose from the fuel tank.
  10. Disconnect the evaporative emission (EVAP) vapor pipe from the EVAP canister.
  11. Disconnect the electrical harness from the multi-way rear body connector and fuel strap.

    12. Object Number: 49897 Size: SH
  12. With the aid of an assistant, support the fuel tank (1).
  13. Disconnect the fuel tank retaining straps.
  14. Lower the fuel tank.
  15. Remove the fuel pump module assembly from the tank. Refer to Fuel Pump Module Replacement .

Installation Procedure

    Object Number: 49897 Size: SH
  1. Install the fuel pump module assembly to the fuel tank. Refer to Fuel Pump Module Replacement .
  2. With the aid of an assistant, raise the fuel tank (1) to the vehicle.

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

  3. Install the fuel tank retaining straps.

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

  4. Connect the wiring harness into the multi-way rear body connector.
  5. Connect the EVAP vapor pipe to the EVAP canister.
  6. Connect the fuel filler hose to the fuel tank.

    7. Tighten
    Tighten the fuel filler hose clamp to 3 N·m (27 lb in).

  7. Install the rubber exhaust hangers.
  8. Install the exhaust heat shield.

    9. Tighten

        • Tighten the exhaust shield bolt to 2 N·m (18 lb in).
        • Tighten the exhaust shield nuts to 1 N·m (9 lb in).
  9. Connect the fuel return pipe and fuel filter quick-connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Lower the vehicle.
  11. Refill the fuel tank.
  12. Install the fuel filler cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  14. Inspect for fuel leaks using the following procedure:
    15. 14.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    14.2. Turn OFF the ignition for 10 seconds.
    14.3. Turn ON the ignition, with the engine OFF.
    14.4. Inspect for fuel leaks.