Service Procedure
The following information provides instructions for inspecting the serial number on the bar code label located on the rear section of the fuel tank.Fuel Tank Inspection
Read the complete inspection procedure before beginning your first inspection.
The bar code label is located on the rear section of the fuel tank and can be viewed using a flashlight from the rear of ALL vehicles (FWD and AWD) as shown above or on a suitable hoist.
The bar code label (1) is located to the right side of a parts label (2). Directly below the bar code is the 14-character serial number.
From underneath the vehicle, read the LAST FOUR numbers of the serial number and compare them to those shown. Example: FS2543R2060.
^ If the LAST FOUR numbers of the serial number MATCH any of those listed above, REPLACE the fuel tank. Refer to the Service Procedure below for information on replacing the fuel tank. Also, refer to the Parts Information section for information on how and where to obtain a replacement fuel tank.
^ If the LAST FOUR number of the serial number DO NOT match any of those listed above, DO NOT replace the fuel tank. Install the GM Recall Identification Label.
Fuel Tank Replacement
This procedure should be used only if the inspection indicated that the fuel tank requires replacement. For additional information and illustrations, refer to the Fuel Tank Replacement Procedure in the appropriate Service Manual or SI Document. Because the replacement fuel tanks in this recall are complete assemblies (include fuel sender, etc.) the labor time allowance is different than that in the labor time guide.
Caution
Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.
After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
1. Relieve the fuel system pressure. For additional information, refer to the Fuel Pressure Relief Procedure in the appropriate Service Manual or SI Document.
2. Drain the fuel tank. For additional information, refer to the Fuel Tank Draining Procedure in the appropriate Service Manual or SI Document.
Caution
To avoid any vehicle damage, serious personal injury, or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being remove.
3. Raise the vehicle on a suitable lift, and support as necessary.
4. Disconnect the fuel tank wiring harness connector (1) at the body pass through.
5. Disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter. For additional information, refer to the Quick Connect Fitting Service Procedure in the appropriate Service Manual or SI Document.
6. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.
7. Disconnect the fuel tank evaporative emission (EVAP) pipe quick-connect fitting near the fuel filter.
8. Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer.
9. Remove the retaining nut for the EVAP canister bracket.
10. Loosen the fuel tank filler pipe hose clamp.
11. Disconnect the fuel tank filler pipe from the fuel tank.
Notice
Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.
12. With the aid of an assistant, support the fuel tank and remove the two fuel tank strap attaching bolts.
13. Remove the fuel tank from the vehicle.
14. With the aid of an assistant, position and support the new fuel tank to the vehicle.
Notice
Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.
15. Position the fuel tank straps and install the two fuel tank retaining strap attaching bolts.
Tighten
Tighten the fuel tank retaining strap bolts to 47 Nm (35 lb-ft).
16. Install the EVAP canister retaining nut.
Tighten
Tighten the EVAP canister retaining nut to 6 Nm (53 lb-in).
Connect the fuel tank filler pipe to the fuel tank.
Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 Nm (22 lb-in).
17. Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
18. Connect the fuel return pipe quick-connect fitting near the fuel filter.
19. Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.
20. Install the fuel feed, fuel return, and the EVAP lines in the fuel pipe retainer.
21. Connect the fuel tank wiring harness connector at the body pass-through.
22. Lower the vehicle.
23. Connect the negative battery cable.
24. Add fuel and reinstall the fuel tank filler pipe cap.
25. Inspect for fuel leaks with the following procedure:
A. Turn ON the ignition for 2 seconds.
B. Turn OFF the ignition for 10 seconds.
C. Turn ON the ignition.
D. Inspect for fuel leaks.
26. Install the GM Recall Identification Label.
27. Prepare the old fuel tank for return to the manufacturer.
Remove the fuel sender shield from the OLD fuel tank.
A. Disconnect the fuel feed, filter return and EVAP pipe quick-connect fittings at the fuel sender.
B. Remove the fuel sender assembly from the old fuel tank.
C. Neutralize and flush the old fuel tank clean.
D. Store the fuel tank to air dry. Do not reinstall the fuel sender or the shield.
E. Store the fuel tank, the fuel sender and the shield until it is picked up by the manufacturer.