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HOMESERVICE MANUALSPONTIAC2006G6 GTP, 2D COUPE, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 230 (ENGINE CONTROLS - 3.5L (L66) INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENTINSTALLATION PROCEDURE
2006 Pontiac G6 GTP, 2D Coupe, Standard

Installation Procedure

2006 Pontiac G6 GTP, 2D Coupe, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2005 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the fuel tank module assemblies. Refer to Fuel Tank Module Replacement - Primary  and Fuel Tank Module Replacement - Secondary .
  2. Install the fuel tank heat shield and fuel tank assembly into the vehicle.
    Fig 1: View Of Fuel Tank Heat Shield & Fuel Tank Assembly Into The Vehicle
    GM927748Courtesy of GENERAL MOTORS CORP.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel tank straps and tighten the bolts.

    Tighten:  Tighten the fuel tank strap-to-body bolts to 25 N.m (18 lb. ft.).

  4. Install the fuel filler pipe, EVAP vent, and fresh air hoses to the fuel tank.
    Fig 2: View Of Fuel Filler Pipe, EVAP Vent & Fresh Air Hoses At Fuel Tank
    GM1347586Courtesy of GENERAL MOTORS CORP.
  5. Connect the electrical connectors:
    1. Fuel tank electrical connector
    2. EVAP solenoid electrical connectors
  6. Tighten the hose clamp on the filler pipe-to-fuel tank connecting hose.

    Tighten:  Tighten the fuel fill neck-to-fuel tank clamp to 5 N.m (44 lb. in.).

  7. Connect the EVAP canister vent and fresh air hoses to the fuel tank hoses.
    Fig 3: View Of Evaporative Emission Canister
    GM1226407Courtesy of GENERAL MOTORS CORP.
  8. If equipped, install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
  9. Install the rubber exhaust hangers.
    Fig 4: Identifying Exhaust Muffler Hangers
    GM892074Courtesy of GENERAL MOTORS CORP.
  10. Lower the vehicle.
  11. Fill the fuel tank with gasoline.
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  13. Prime the fuel system:
    1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
    2. Repeat the previous step twice.
    3. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    4. If the engine does not start, repeat steps 13.1-13.3.
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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.