Fuel Tank Assembly

REMOVAL PROCEDURE
1. Relieve the fuel system fuel pressure.
2. Drain the fuel tank (1).
3. Raise the vehicle.
4. Remove the exhaust system.
5. Remove the wheel house filler pipe (1) opening cover in order to gain access to the fuel tank filler pipe.
6. Remove the fuel tank filler pipe attaching screws (2).
7. Remove the fuel tank tiller pipe (1) hose clamps and the fuel tank filler pipe.
8. Remove the height sensor connector. Remove the height sensor if necessary. Refer to Electronic Level Control System.
9. Remove the fuel feed, fuel return, and vapor pipes near the fuel filter.
10. Remove the EVAP pipes and retainers at the evaporative emission canister.
11. Remove the rear suspension support assembly. Refer to Rear Suspension.
12. Remove the fuel tank bolts (3) from the fuel tank (2) straps.
13. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.

DISASSEMBLE PROCEDURE
1. Disassemble the harness retaining straps (2).
2. Disassemble the fuel feed, fuel return, and EVAP hoses.
3. Disassemble the fuel sender assembly.

ASSEMBLE PROCEDURE
1. Assemble the fuel sender assembly. Refer to Fuel Sender Assembly
2. Assemble the fuel feed, fuel return, and EVAP hoses.
3. Assemble the harness retaining straps (2).
4. Assemble the fuel tank filler pipe and fuel tank filler pipe clamps.

INSTALLATION PROCEDURE

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application.

General Motors will call out those fasteners that require a replacement after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant.

UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener.

When you install fasteners, use the correct tightening sequence and specifications.

Following these instructions can help you avoid damage to parts and systems.

1. Position and support the fuel tank (4) with the aid of an assistant.
2. Install the fuel tank straps (2).
- Tighten the fuel tank strap bolts (3). Tighten the bolts to 48 Nm (35 lb ft).
3. Install the rear suspension support assembly bolts and the lower suspension support assembly. Refer to Rear Suspension.
4. Install the EVAP pipes and retainers at the evaporative emission canister.
5. Install the fuel feed, fuel return, and vapor pipes near the fuel filter. Refer to Servicing Quick Connect Fittings.
6. Install the fuel tank filler pipe hose clamps and the fuel tank filler pipe.
7. Install the height sensor connector. Refer to Electronic Level Control System.
8. Install the fuel tank filler pipe (1) attaching screws (2).
9. Install the wheel house filler pipe opening cover.
10. Install the exhaust system. Refer to Exhaust System.
11. Lower the vehicle.
12. Add fuel and install the fuel tank filler pipe (1) cap.
13. Install the negative battery cable.
14. Inspect for leaks.
- Turn the ignition switch to the ON position for 2 seconds.
- Turn the ignition switch to the OFF for 10 seconds.
- Turn the ignition switch to the ON position.
- Check for fuel leaks.