Fuel Tank: Installation

2004 Oldsmobile Bravada RWDSECTION Installation
WARNING: This page is about a different car, the 2003 Pontiac Grand Am and 2003 Oldsmobile Alero. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the fuel sender assembly to the fuel tank. See FUEL SENDER ASSEMBLY  .
  2. With the aid of an assistant, raise the fuel tank to the vehicle.
  3. Install the fuel tank retaining straps. Tighten the strap bolts to specification. See TORQUE SPECIFICATIONS  .
  4. Connect the wiring harness into the multiway rear body connector.
  5. Connect the EVAP vapor pipe to the EVAP canister.
  6. Connect the fuel filler hose to the fuel tank. Tighten the fuel filler hose clamp to specification. See TORQUE SPECIFICATIONS  .
  7. Install the rubber exhaust hangers.
  8. Install the exhaust heat shield. Tighten the exhaust shield bolt/nuts to specification. See TORQUE SPECIFICATIONS  .
  9. Connect the fuel return pipe and fuel filter quick-connect fittings.
  10. Lower the vehicle.
  11. Refill the fuel tank.
  12. Install the fuel filler cap.
  13. Connect the negative battery cable. Tighten to specification. See TORQUE SPECIFICATIONS  .
  14. Inspect for leaks by using the following procedure.
    • Turn ignition switch to RUN position, with the engine OFF for 2 seconds.
    • Turn ignition switch to OFF position for 10 seconds.
    • Turn ignition switch to RUN position, with the engine OFF.
    • Check for fuel leaks.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • You smell fuel, burning insulation, or see smoke.
  • Brakes feel soft, pull hard to one side, or make grinding noises.
  • The engine overheats, stalls repeatedly, or misfires under load.
  • You are missing required tools, torque specs, or safe lifting equipment.
  • You are not confident in the next step or safety outcome.