GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Aveo 🢒 General Information 🢒 General Information 🢒 Fuel Tank Replacement

Removal Procedure

    Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.


    Object Number: 1376156 Size: SH
  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: 1376157 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: 1376158 Size: SH
  9. Disconnect the fuel line near the right front of the fuel tank.
  10. Disconnect the wiring harness clips and the fuel line clips as needed.

    11. Object Number: 1376159 Size: SH
  11. Remove the front exhaust pipe. Refer to Front Pipe Replacement .

    12. Object Number: 1376160 Size: SH
  12. Support the fuel tank.
  13. Remove the fuel tank retaining nuts.
  14. Carefully lower the fuel tank.
  15. Remove the fuel tank.
  16. Transfer any parts as needed.

Installation Procedure

    Object Number: 1376160 Size: SH
  1. Raise the fuel tank into position.

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

    Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.

  2. Install the fuel tank mounting straps and bolts.

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

  3. Connect the fuel 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 the fuel tank vent tube.
  8. Install the fuel tank filler tube clamp at the fuel tank.
  9. Install the front exhaust pipe. Refer to Front Pipe Replacement .

    10. Object Number: 1376159 Size: SH
  10. Install the parking brake cable retainer clamps and the support.

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

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