Mike's Workshop Manuals: Service manuals for every vehicle
Home >> Pontiac >> 2004 >> Aztek Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 120 (Engine Control System - 4.8L, 5.3L, & 6.0L - Introduction) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 Chevrolet TrailBlazer, and 2004 Buick Rainier. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Tank & Related Components
    GM887435Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, position and support the fuel tank.
  2. Connect the fuel sender electrical connector (1).
    3. Fig 2: Removing/Installing Fuel Tank Straps
    GM887432Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel tank straps (2).
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel tank strap bolts (1).

    Tighten:  Tighten the bolts to 32 N.m (24 lb ft).

    5. Fig 3: Locating Fuel Tank Fittings
    GM899732Courtesy of GENERAL MOTORS CORP.
  5. Remove the caps from the fuel and EVAP pipes.
  6. Connect the fuel feed, return and EVAP pipes. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. Fig 4: View Of Fuel Tank & Related Components
    GM887435Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel tank pressure sensor electrical connector (3).
  8. Connect the EVAP vent valve electrical connector (2).
    9. Fig 5: Identifying Fuel Pipe/Hose Components
    GM730806Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel hose (2) to the fuel tank.

    Tighten:  Tighten the clamp (1) to 2.5 N.m (22 lb in).

  10. Lower the vehicle.
  11. Refill the fuel tank.
  12. Install the fuel fill cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  14. Inspect for leaks.
    1. Turn the ignition ON, with the engine OFF for 10 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
  15. Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (TrailBlazer, Envoy) or Fuel Tank Shield Replacement (TrailBlazer EXT, Envoy XL) in Frame and Underbody.
  16. Install the frame brace. Refer to Frame Brace Replacement (TrailBlazer, Envoy, Bravada) or Frame Brace Replacement (TrailBlazer EXT, Envoy XL) in Frame and Underbody.
  17. Lower the vehicle.
scientia non olet · About Mike's Workshop Manuals