Fuel - Corrected Tank Replacement

89pontiac03

Bulletin Number: 89-6-25
Reference Number: 816303R
Publish Date: 2/89
Subject: SERVICE MANUAL UPDATE - SECTION 6C-ENGINE FUEL - (FUEL TANK REPLACEMENT)

Models
Affected: 1988 - 1989 GRAND PRIXS
The Service Manual procedure for fuel tank removal is incorrect for all 1988-1989 Grand Prix vehicles. The corrected procedure is as follows:

CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

Fuel Tank Removal:

1. Disconnect negative battery terminal.
2. Relieve fuel system pressure, see "Fuel System Pressure Relief" in ENGINE FUEL (SECTION 6C).
3. Raise vehicle.
4. Remove all fuel from tank, see "Draining Fuel Tank" in ENGINE FUEL (SECTION 6C).
5. Disconnect fuel filler hose/vent hose assembly at tank.

CAUTION: A small amount of fuel may be released when disconnecting fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place towel in an approved container when disconnect is completed.

6. Disconnect fuel feed pipe at fuel filter inlet and move aside.
7. Disconnect fuel return pipe at braided hose connection and move aside.
8. Disconnect vapor purge hose at connection in front of tank.
9. Disconnect rubber exhaust pipe hangers to allow exhaust system to drop slightly.
10. Remove exhaust pipe heat shield bolts (3) and heat shield.
11. Disconnect tank sender unit electrical connector (located next to fuel filler pipe.
12. Support tank, and disconnect front bolts retaining fuel tank straps.

NOTICE: Do not bend fuel tank straps, as this may damage straps.

13. Lower tank enough to disconnect fuel sender harness retaining clips (2).
14. Disconnect fuel tank vent hose from sender:
15. Disconnect vapor purge hose from vapor tubing.
16. Remove tank from vehicle.
17. Transfer sender assembly and insulator pads to replacement tank.

Fuel Tank Installation:

- Reverse removal procedure.

Tighten:

- Front fuel tank strap bolts to 47 N-m (35 ft.lbs.)
- Fuel Line connections to 30 N-m (22 ft.lbs.)