LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Pontiac >> 2004 >> Grand Prix GTP >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls (Introduction) - 3.8L >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removal Procedure

    NOTE: Refer to Cover and Plug Openings Notice in Cautions and Notices.
    IMPORTANT: Always maintain cleanliness when servicing the fuel system components.
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Loosen the fuel filler hose clamp (1) at the fuel tank (3).
    5. Fig 1: Identifying Fuel Tank Components
    GM186674Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel tank filler hose from the fuel tank.
    6. Fig 2: Fuel Tank Filler Hose
    GM155468Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel feed (4), the fuel return (2) and the evaporative emission (EVAP) (3) pipes at the fuel filter area. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. Fig 3: Identifying In-Line Fuel Filter
    GM911091Courtesy of GENERAL MOTORS CORP.
  7. Support the exhaust system.
  8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
  9. Separate the two halves of the EVAP fresh air hose at the splice.
    10. Fig 4: EVAP Fresh Air Hose
    GM698635Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel tank shield push pins (2).
    11. Fig 5: Fuel Tank Shield
    GM699555Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel tank shield (3).
    12. NOTE: Do not bend the fuel tank straps as this may damage the straps.
  12. Support the fuel tank with a suitable jack.
  13. Remove the fuel tank strap bolts (2).
  14. Using the suitable jack lower the fuel tank.
  15. Disconnect the fuel sender assembly electrical connectors.
    16. Fig 6: View Of Fuel Tank
    GM699556Courtesy of GENERAL MOTORS CORP.
  16. Remove the fuel tank and place the tank in a suitable work area.
    17. IMPORTANT: Note the routing of the pipe assemblies and the retaining clips for installation.
  17. Disconnect and remove the fuel feed (6), the fuel return (7), and the EVAP pipe (5) assemblies and the insulator clips from the fuel tank (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  18. Remove the EVAP canister (2) from the fuel tank (1).
    19. Fig 7: Fuel Tank & Fuel Hoses/Pipes
    GM911093Courtesy of GENERAL MOTORS CORP.
  19. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.
scientia non olet · About LEMON Manuals