GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Spark 🢒 Vehicle Control Systems 🢒 Vehicle DTC Information 🢒 Fuel Tank Replacement

Removal Procedure

    Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

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


    Object Number: 1225057 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Disconnect the fuel tank ventilation tube clamp (2).
  3. Disconnect the fuel tank ventilation tube (1).

    4. Object Number: 1225048 Size: SH
  4. Place a pan below the fuel tank to catch the draining fuel.
  5. Disconnect the fuel tank filter tube (1).
  6. Drain the fuel from the fuel tank using the ventilation tube joint port (2).
  7. Disconnect the evaporative emission canister line (3).

    8. Object Number: 1225051 Size: SH
  8. Remove the fuel filter. Refer to Fuel Filter Replacement .
  9. Install the jack on the center of the fuel tank.
  10. Remove the fuel tank strap bolts (1).
  11. Remove the fuel tank straps (2).

    12. Object Number: 1225040 Size: SH
  12. Lower slowly the jack to remove the fuel tank easily (1).
  13. Disconnect the canister hose which is connected to the roll over valve from the fuel tank removed (2).
  14. Inspect the fuel tank for clacks, damages, and contaminations.
  15. Inspect the fuel lines for cracks and damages.
  16. Remove the fuel tank.

Installation Procedure

    Object Number: 1225040 Size: SH
  1. Connect the canister hose to the roll over valve. Connect to the fuel tank (2).
  2. Slowly raise the fuel tank on the jack (1).

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


    Object Number: 1225051 Size: SH
  3. Install fuel tank straps (2).

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

  4. Install fuel tank strap bolts (1).

    5. Tighten
    Tighten the fuel tank strap bolts to 18-22 N·m (13-16 lb ft).

  5. Remove the fuel tank jack.
  6. Install the fuel filter. Refer to Fuel Filter Replacement .
  7. Connect the evaporative emission canister line (3).
  8. Connect the fuel tank filter tube.

    9. Object Number: 1225057 Size: SH
  9. Connect the fuel tank ventilation tube (1).
  10. Connect the fuel tank ventilation tube clamp (2).
  11. Fill the tank with fuel.
  12. Turn the ignition ON and inspect the fuel system for leaks.