Fuel Tank Replacement
REMOVAL PROCEDURENOTE: Refer to Cover and Plug Openings Notice in Service Precautions.
IMPORTANT: Always maintain cleanliness when servicing the 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. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Loosen the fuel filler hose clamp (1) at the fuel tank (3).
5. Remove the fuel tank filler hose from the fuel tank.
6. Disconnect the fuel feed and the return pipes at the fuel filter and the fuel filter area.
7. Disconnect the evaporative emission (EVAP) pipe from the connection at the front of the fuel tank.
8. Support the exhaust system.
9. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
10. Separate the two halves of the EVAP fresh air hose at the splice.
11. Remove the fuel tank shield push pins (2).
12. Remove the fuel tank shield (3).
NOTE: Do not bend the fuel tank straps as this may damage the straps.
13. Support the fuel tank with a suitable jack.
14. Remove the fuel tank strap bolts (2).
15. Remove the fuel tank from the vehicle.
16. Place the fuel tank in a suitable work area.
Fuel Tank:
17. If the fuel tank is not being replaced, go to the Fuel Tank Installation Procedure.
18. Remove the EVAP canister.
19. Remove the fuel feed, the fuel return, and EVAP pipe assemblies and the insulator clips from the fuel tank.
20. Remove the insulator pad from the fuel tank. Note the location of the insulator pad for the installation.
INSTALLATION PROCEDURE
Fuel Tank:
1. Install the insulator pad on the fuel tank.
NOTE:
^ 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 Fluoroelastomer or GM 6163M on the hose.
2. Install the fuel feed, the fuel return, and the EVAP pipe assemblies and the insulator clips.
3. Install the EVAP canister.
4. Install the fuel tank to a suitable jack.
5. Raise the fuel tank to the original position.
NOTE: Refer to Fastener Notice in Service Precautions.
6. Install the bolts (2) to the fuel tank retaining straps (3).
Tighten
Tighten the bolts to 48 N.m (35 lb ft).
7. Position the tank shield (3), and install the 3 push pins (2).
8. Connect the quick-connect fittings at the fuel filter and fuel filter area.
NOTE:
^ 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 Fluoroelastomer or GM 6163M on the hose.
9. Connect the EVAP pipe at the front of the fuel tank.
10. Install the fuel tank filler hose to the fuel tank.
11. Install the two parts of the EVAP fresh air hose at the splice.
12. Fully seat the filler hose (4) on the fuel tank port (2).
13. Ensure that the clamp (1) is properly located on the tank port between the bead (5) and the tank (3).
Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).
14. Raise the exhaust to the original position.
15. Install the rubber exhaust pipe hangers.
16. Lower the vehicle.
17. Install the fuel sender assembly.
18. Add fuel and install the fuel filler pipe cap.
19. Connect the negative battery cable.
20. Inspect the fuel system for leaks by performing the following steps:
20.1. Turn ON the ignition for 2 seconds.
20.2. Turn OFF the ignition for 10 seconds.
20.3. Turn ON the ignition.
20.4. Inspect for fuel leaks.