2004 Chevrolet Monte Carlo LSFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install the insulator pad on the fuel tank.
    2. NOTE:
    • Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle.
    • Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes.
    • Replace the vapor pipes with original equipment or parts that meet GM specifications.
    • Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the hose.
  2. Install the fuel feed, the fuel return, and the EVAP pipe assemblies and the insulator clips.
  3. Install the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
    4. Fig 1: View OF Fuel Tank & EVAP Canister
    GM531026Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel tank to a suitable jack.
  5. Raise the fuel tank to the original position.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel tank strap bolts (2).

    Tighten:  Tighten the bolts to 48 N.m (35 lb ft).

    7. Fig 2: Installing Fuel Tank
    GM699556Courtesy of GENERAL MOTORS CORP.
  7. Position the tank shield (3), and install the push pins (2).
    8. Fig 3: Installing Fuel Tank Shield
    GM699555Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel feed, the fuel return and the EVAP pipes quick-connect fittings at the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    9. Fig 4: Connecting Quick-Connect Fittings
    GM32401Courtesy of GENERAL MOTORS CORP.
  9. Install the 2 halves of the EVAP fresh air hose at the splice.
    10. Fig 5: Installing 2 Halves Of EVAP Fresh Air Hose
    GM698635Courtesy of GENERAL MOTORS CORP.
  10. Install the fuel tank filler hose to the fuel tank.
    11. Fig 6: Fuel Tank Filler Hose
    GM155468Courtesy of GENERAL MOTORS CORP.
  11. Fully seat the filler hose (4) on fuel tank port (2).
  12. Ensure the clamp (1) is properly located on tank port between the bead (5) and the tank (3).

    Tighten:  Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).

    13. Fig 7: Identifying Fuel Tank Components
    GM186674Courtesy of GENERAL MOTORS CORP.
  13. Raise the exhaust to the original and install the exhaust pipe hangers.
  14. Lower the vehicle.
  15. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  16. Add fuel and install the fuel filler pipe cap.
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  18. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, for 2 seconds.
    2. Turn OFF the ignition, for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
Factory Service Tools

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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.

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