Fuel Tank Replacement

Removal Procedure

Cautions:
- Provide additional support when a vehicle is on a hoist:
- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

Notice: Do not attempt to straighten the kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

Notice: Do not bend the fuel tank straps as this may damage the straps.

Notice:
- 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 Fluroelastomer or GM 6163M on the hose.
Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Important: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.

Important: Always maintain cleanliness when servicing fuel system components.


1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement
4. Raise the vehicle.




5. Loosen the fuel tank filler hose clamp (1) at the fuel tank (3).




6. Remove the fuel tank filler hose from the fuel tank.

Descriptive:

7. Remove the quick-connect fittings at the fuel tank. Refer to Quick Connect Fitting(s) Service (Metal Collar).
8. Remove the EVAP pipe from the connection at the front of the fuel tank.
9. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.





10. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.




11. Disconnect the EVAP pipes from the rear of the fuel tank.
12. Disconnect the EVAP pipe from the fuel limiter vent valve.
13. Disconnect the fuel filler neck EVAP pipe at the rear of the fuel tank.
14. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
15. If the fuel tank is not being replaced, go to Fuel Tank Installation Procedure.

Descriptive:

16. Remove the fuel feed, fuel return, and EVAP pipe assemblies and the insulator clips from the fuel tank.
17. Remove the fill limiter vent valve from the fuel tank. Refer to Fill Limiter Vent Valve Replacement.





18. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.

Installation Procedure
1. Install the insulator pads on the fuel tank.
2. Install the fill limiter vent valve. Refer to Fill Limiter Vent Valve Replacement
3. Install the fuel feed, fuel return, and EVAP pipe assemblies and the insulator clips.
4. With the aid of an assistant, position and support the fuel tank.
5. Connect the EVAP pipes to the rear of the fuel tank.
6. Connect the EVAP pipe to the fuel limiter vent valve.
7. Connect the fuel filler EVAP pipe at the rear of the fuel tank.
8. Install the fuel tank retaining strap attaching bolts (2).
Tighten
Tighten the front fuel tank retaining strap bolts (2) to 47 Nm (35 lb. ft.).

Notice: Refer to Fastener Notice in Service Precautions.

9. Install the quick-connect fittings at the fuel tank. Refer to Quick Connect Fitting(s) Service (Metal Collar).
10. Install the EVAP pipe at the front of the fuel tank.
11. Install the fuel tank filler hose to the fuel tank.
12. Inspect and make sure filler hose (4) is fully seated on fuel tank port (2).
13. Make sure clamp (1) is properly located on tank port between the feed (5) and tank (3).
Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 Nm (22 lb. in.).

Notice: Refer to Fastener Notice in Service Precautions.

14. Install the rubber exhaust pipe hangers.
15. Inspect the fuel and EVAP pipes making sure they were not kinked or damaged during removal and installation.
16. Lower the vehicle.
17. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement.
18. Add fuel and install the fuel tank filler pipe cap.
19. Install the negative battery cable.
20. Inspect for leaks.
20.1. Inspect turn the ignition switch to the ON position for two seconds.
20.2. Turn the ignition switch to the OFF for ten seconds.
20.3. Turn the ignition switch to the ON position again.
20.4. Visually inspect the fuel system for fuel leaks.