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HOMESERVICE MANUALSBUICK2005LESABRE LIMITED, 4T65E/M15REPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROLS - INTRODUCTIONREPAIR INSTRUCTIONSFUEL TANK REPLACEMENTINSTALLATION PROCEDURE
2005 Buick LeSabre Limited, 4T65E/M15

Installation Procedure

2005 Buick LeSabre Limited, 4T65E/M15SECTION Installation Procedure
    Fig 1: Removing/Installing Fuel Tank Strap Bolts & Fuel Tank
    GM104646Courtesy of GENERAL MOTORS CORP.
  1. Position and support the fuel tank (5) with the aid of an assistant.
  2. Install the fuel tank straps (2).
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel tank strap bolts (4).

    Tighten:  Tighten the fuel tank strap bolts to 42 N.m (31 lb ft).

    4. Fig 2: Disconnecting/Reconnecting Fuel Tank Electrical Connector
    GM684415Courtesy of GENERAL MOTORS CORP.
  4. Connect the fuel tank electrical connector.
  5. Install the fuel tank electrical harness into the retainers.
    6. Fig 3: Removing/Installing Fuel & EVAP Retainer At Frame
    GM684413Courtesy of GENERAL MOTORS CORP.
  6. Install the fuel and EVAP retainer to the frame.
    7. Fig 4: View Of EVAP Pipe To Canister
    GM104621Courtesy of GENERAL MOTORS CORP.
  7. Connect the EVAP pipe (2) to the EVAP canister.
    8. Fig 5: View Of Fuel Filter Quick Connections
    GM483018Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel feed pipe (4) and the fuel return pipe (1). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  9. Install the rear suspension support assembly. Refer to Support Replacement - Rear in Frame and Underbody.
    10. Fig 6: Removing/Installing Fuel Cap & Fuel Filler Tube Sealing Ring
    GM891295Courtesy of GENERAL MOTORS CORP.
  10. Connect the fuel filler hose (4) to the fuel filler pipe (3).

    Tighten:  Tighten the clamp to 3.5 N.m (31 lb in).

  11. Install the wheelhouse filler pipe opening cover (5).
  12. Lower the vehicle.
  13. Add fuel to the fuel tank.
  14. Install the fuel tank filler pipe cap.
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  16. Inspect for leaks.
    1. Turn ON the ignition switch for 2 seconds.
    2. Turn OFF the ignition switch for 10 seconds.
    3. Turn ON the ignition switch.
    4. Inspect for fuel leaks.
  17. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36) in Engine Mechanical - 3.8L.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.