Removal and Replacement

FUEL TANK REPLACEMENT (TrailBlazer, Envoy, Rainier)

REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Raise the vehicle. Refer to Vehicle Lifting.
3. Remove the frame brace.
4. Remove the fuel tank shield, if equipped.
5. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.




6. Disconnect the evaporative emission (EVAP) canister fresh air pipe.
7. Disconnect the EVAP canister solenoid pipe.
8. Disconnect the EVAP purge pipe.




9. Disconnect the fuel filler pipe recirculation hose from the fuel tank.
10. Loosen the clamp securing the fuel fill pipe to the fuel tank.
11. Disconnect the fuel fill pipe from the fuel tank.




12. Disconnect the fuel feed pipe (2) and EVAP pipe (1) from the fuel tank.
13. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
14. Support the fuel tank.




15. Remove the fuel tank strap attaching bolts.

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions.

16. Remove the fuel tank straps.
17. Carefully lower the fuel tank.




18. Disconnect the EVAP vent valve electrical connector (8).
19. Disconnect the fuel tank pressure sensor electrical connector (2).
20. Disconnect the fuel sender electrical connector (1).
21. Remove the fuel tank.
22. Place the fuel tank in a suitable work area.
23. If the fuel tank is not being replaced, go to the Installation Procedure.

DISASSEMBLY PROCEDURE




1. Cut and remove the tie (2) securing the fuel feed pipe and EVAP canister purge pipe together.
2. Remove the fuel feed pipe (1) from the fuel sender module (4) and retaining clip (3).




3. Cut and remove the tie (1) securing the EVAP pipes together.
4. Disconnect the EVAP pipe assembly (3) from the tank vent valves and fuel sender.
5. Remove the EVAP pipe assembly (3) from the tank.
6. Remove the EVAP canister purge pipe (2) from the fuel tank.




7. Remove the EVAP vent valve (8).
8. Remove the fuel sender assembly (4) from the fuel tank.

ASSEMBLY PROCEDURE




1. Install the fuel sender assembly (4) to the fuel tank.
2. Install the EVAP vent valve (8).




3. Install the EVAP canister purge pipe (2) to the fuel tank.
4. Install the EVAP pipe assembly (3) to the fuel tank.
5. Connect the EVAP pipe assembly (3) to the tank vent valves and fuel sender.
6. Install a new tie (1) to secure the EVAP pipes together.




7. Install the fuel feed pipe (1) to the fuel sender module (4) and retaining clip (3).
8. Install a new tie (2) securing the fuel feed pipe and EVAP canister purge pipe together.

INSTALLATION PROCEDURE
1. Support the fuel tank.




2. Connect the fuel sender electrical connector (1).
3. Connect the EVAP vent valve electrical connector (2).
4. Connect the fuel pressure sensor electrical connector (8).




5. Install the fuel tank straps.
6. Install the fuel tank strap attaching bolts.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the bolts to 32 N.m (24 lb ft).




7. Remove the caps from the fuel and EVAP pipes.
8. Connect the fuel feed pipe (1) and the EVAP pipe (2).




9. Connect the fuel fill pipe to the fuel tank.

Tighten the fuel fill hose clamp to 2.5 N.m (22 lb in).

10. Connect the fuel filler pipe recirculation hose to the fuel tank.




11. Connect the EVAP purge pipe.
12. Connect the EVAP canister solenoid pipe.
13. Connect the EVAP canister fresh air pipe.
14. Lower the vehicle.
15. Refill the fuel tank.
16. Install the fuel filler cap.
17. Connect the negative battery cable.
18. Raise the vehicle. Refer to Vehicle Lifting.
19. Inspect for leaks.
1. Turn ON the ignition, with the engine OFF for 10 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.
20. Install the fuel tank shield, if equipped.
21. Install the frame brace.
22. Lower the vehicle.