GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1997 🢒 Firefly (Canada) 🢒 Engine 🢒 Engine Controls - 1.3L 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 55723 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Remove the rear seat cushion from the vehicle.
  4. Disconnect the fuel pump, fuel level sensor (fuel gauge sending unit), and fuel tank pressure sensor electrical connectors.
  5. Push electrical connectors (2) through the grommet (1) in the floor.
  6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    7. Object Number: 237943 Size: SH
  7. Remove the one clamp and the fuel filler hose (2) from the fuel filler neck
  8. Remove the one clamp and the fuel breather hose (3) from the fuel filler neck.
  9. Remove the one clamp and the fuel feed inlet hose from the fuel filter.
  10. Remove the one clamp and the fuel return hose from the fuel return pipe.
  11. Remove the one clamp and the fuel vapor hose from the fuel vapor pipe.
  12. Remove the four fuel tank mounting bolts and fuel tank from vehicle underbody.

Inspection Procedure
    • Inspect the fuel pump assembly hose connections for signs of leaks, loose fittings, deterioration or damage.
    • Inspect the fuel pump assembly and the fuel level sensor gaskets for signs of leaks.
    • Inspect the fuel tank for signs of damage that may cause leaks.
    • Clean or replace components/assemblies as required.

Disassembly Procedure
  1. Remove the clamp and the fuel feed hose from fuel feed pipe on the fuel tank.
  2. Remove the clamp and the fuel return hose from fuel return pipe on the fuel tank.
  3. Remove the clamp and the fuel vapor hose from fuel vapor pipe on the fuel tank.
  4. Remove the clamp and the fuel filler hose from the fuel tank.
  5. Remove the clamp and the fuel breather hose from the fuel tank.
  6. Remove the five screws and the fuel level sensor from the fuel tank.
  7. Remove the seven screws and the fuel pump assembly including the fuel feed and fuel return pipes from the fuel tank.
  8. Remove the twelve screws and the fuel cut valves with the fuel vapor separator assembly from the fuel tank.
  9. Remove the one screw and the fuel return volume assembly from the fuel tank (If equipped with the EVAP Tank Pressure Control Solenoid Vacuum Valve).

Assembly Procedure
  1. Connect the fuel filler hose to the fuel tank and secure with one clamp.
  2. Connect the fuel breather hose to the fuel tank and secure with one clamp.
  3. Install the fuel cut valves with the fuel vapor separator assembly to the fuel tank and secure with twelve screws.
  4. Install the one screw and the fuel return volume assembly from the fuel tank (If equipped with the EVAP Tank Pressure Control Solenoid Vacuum Valve).
  5. Install the fuel pump assembly including the fuel feed and the fuel return pipes to the fuel tank and secure with seven screws.
  6. Install the fuel level sensor to the fuel tank and secure with five screws.
  7. Connect the fuel vapor hose to the fuel vapor pipe on the fuel tank and secure with one clamp.
  8. Connect the fuel return hose to the fuel return pipe on the fuel tank and secure with one clamp.
  9. Connect the fuel feed hose to the fuel feed pipe on the fuel tank and secure with one clamp.

Installation Procedure

    Object Number: 237943 Size: SH
  1. Install the fuel tank to the vehicle underbody and secure with four mounting bolts.

    2. Tighten
    Tighten the fuel tank mounting bolts to 25 N·m (18 lb ft).

  2. Connect the fuel vapor hose to the fuel vapor pipe and secure with one clamp.
  3. Connect the fuel return hose to the fuel return pipe and secure with one clamp.
  4. Connect the fuel feed inlet hose to the fuel filter and secure with one clamp.
  5. Connect the fuel breather hose (3) to the fuel filler neck and secure with one clamp.
  6. Connect the fuel filler hose (2) to the fuel filler neck and secure with one clamp.

    7. Object Number: 55723 Size: SH
  7. Push the fuel pump and the fuel level sensor electrical connectors (2) up through the grommet (1) in the floor.
  8. Lower the vehicle.
  9. Connect the fuel pump and the fuel level sensor electrical connectors.
  10. Install the rear seat cushion to the vehicle.
  11. Refill the fuel tank.
  12. Connect the negative (-) battery cable.

    13. Tighten
    Tighten the negative (-) battery cable-to-negative (-) battery terminal retainer to 5.5 N·m (4 lb ft).

  13. Turn ON the ignition in order to pressurize the fuel system.
  14. Turn OFF the ignition.
  15. Check for any fuel leaks and repair as necessary.