GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Aveo 🢒 Engine 🢒 Engine Controls - 1.4L DOHC 🢒 Fuel Tank Replacement

Removal Procedure

    Notice: Refer to Fuel Pressure Notice in the Preface section.


    Object Number: 1241914 Size: SH

    Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Relieve the fuel pressure. Refer to Fuel Pressure Relief .

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the negative battery cable.
  3. Drain the fuel tank.
  4. Disconnect the parking brake cable retainer clamps and the support along the fuel tank to provide clearance for the tank.

    5. Object Number: 1241916 Size: SH
  5. Remove the fuel tank filler tube clamp at the fuel tank.
  6. Disconnect the fuel tank filler tube.
  7. Disconnect the fuel tank filler tube at the fuel tank.
  8. Disconnect the canister vapor tube at the control valve vapor tube.

    9. Object Number: 1241917 Size: SH
  9. Disconnect the fuel pump harness connector at the right rear corner of the fuel tank.
  10. Disconnect the fuel inlet line near the right front of the fuel tank.
  11. Disconnect the wiring harness clips and the fuel line clips as needed.

    12. Object Number: 1241919 Size: SH
  12. Support the fuel tank.
  13. Remove the fuel tank retaining bolts.
  14. Carefully lower the fuel tank.
  15. Remove the fuel tank.
  16. Transfer any parts as needed.

Installation Procedure

    Object Number: 1241916 Size: SH
  1. Raise the fuel tank into position.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the fuel tank mounting bolts.

    3. Tighten
    Tighten the fuel tank retaining bolts to 20 N·m (15 lb ft).

  3. Connect the fuel outlet line.
  4. Connect the wiring harness clips and the fuel line clips as needed.
  5. Connect the fuel pump electrical connector.
  6. Connect the fuel vapor line.
  7. Connect the fuel tank filler tube and fuel tank vent tube.
  8. Install the fuel tank filler tube clamp at the fuel tank.

    9. Object Number: 1241914 Size: SH
  9. Install the parking brake cable retainer clamps and the support.

    10. Tighten
    Tighten the parking brake cable retainer clamps to 10 N·m (89 lb in).

  10. Connect the negative battery cable.
  11. Fill the fuel tank.
  12. Perform a leak check of the fuel tank and the fuel line connections.