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Fuel Tank: Installation

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install fuel tank (3).
  2. Install fuel tank straps (2) and the 4 bolts (1). Tighten bolts to specification. See TORQUE SPECIFICATIONS  . See Figure .
  3. Connect EVAP vapor line (1) to EVAP canister. See Figure .
  4. Connect filler pipe vent line (1) to the FLVV (2). See Figure .
  5. Connect ORVR vent line (1) to the FLVV. See Figure .
  6. Connect filler pipe vent line (1) to fuel tank (2). See Figure .
  7. Connect fuel filler hose (2) to the fuel tank.
  8. Secure fuel filler hose (2) to the fuel tank with the hose clamp (1). See Figure .
  9. Connect fuel supply line.
  10. Secure right side parking brake cable (2) with 2 bolts (1). Tighten bolts to specification. See TORQUE SPECIFICATIONS  . See Figure .
  11. Secure left side parking brake cable (2) with 2 bolts (1). Tighten bolts to specification. See TORQUE SPECIFICATIONS  . See Figure .
  12. Install rear exhaust heat shield (2).
  13. Secure rear exhaust heat shield (2) with the 2 left side bolts (1) and 3 right side bolts (3). Tighten bolts to specification. See TORQUE SPECIFICATIONS  . See Figure .
  14. Install the catalytic converter and intermediate exhaust pipe assembly to the vehicle.
  15. Lower vehicle.
  16. Install fuel tank vapor line (2) to fuel sender fitting.
  17. Install fuel supply line (3) to fuel sender fitting.
  18. Secure fuel supply line (3) using the retaining clip (1).
  19. Connect fuel sender harness connector (1) to fuel sender assembly.
  20. Connect FTP sensor harness connector (2) to fuel sender assembly.
  21. Add fuel to fuel tank.
  22. Connect negative battery cable. Tighten clamp bolt to specification. See TORQUE SPECIFICATIONS  .
  23. Turn ignition switch to RUN position to pressurize the fuel system and check for leaks.
  24. Inspect butyl caulk seal for the fuel sender access panel. Replace any missing butyl caulk as necessary.
  25. Install access panel to rear seat floor.
  26. Relocate carpet under the seat and left sill plate area.
  27. Install sill plate to left side door opening.
  28. Install rear seat bottom cushion.
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