Fuel Tank Replacement

Fuel Tank Replacement

Removal Procedure


Notice: Refer to Cover and Plug Openings Notice.


Important: Always maintain cleanliness when servicing the fuel system components.


1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)).
2. Drain the fuel tank. Refer to Fuel Tank Draining (Service and Repair).
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




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 (4), the fuel return (2) and the evaporative emission (EVAP) (3) pipes at the fuel filter area. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
7. Support the exhaust system.
8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.




9. Separate the two halves of the EVAP fresh air hose at the splice.




10. Remove the fuel tank shield push pins (2).
11. Remove the fuel tank shield (3).





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

12. Support the fuel tank with a suitable jack.
13. Remove the fuel tank strap bolts (2).
14. Using the suitable jack lower the fuel tank.
15. Disconnect the fuel sender assembly electrical connectors.
16. Remove the fuel tank and place the tank in a suitable work area.





Important: Note the routing of the pipe assemblies and the retaining clips for installation.


17. Disconnect and remove the fuel feed (6), the fuel return (7), and the EVAP pipe (5) assemblies and the insulator clips from the fuel tank (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
18. Remove the EVAP canister (2) from the fuel tank (1).
19. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.



Installation Procedure





1. Install the insulator pads to the fuel tank.
2. Install the EVAP canister (2) to the fuel tank (1).

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 Fluoroelastomer or GM 6163M on the hose.


3. Install and connect the fuel feed (6), the fuel return (7), and the EVAP pipe (5) assemblies and the insulator clips to the fuel tank (1) as noted during removal. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




4. Install the fuel tank to a suitable jack.
5. Raise the fuel tank (1) to the original position.

Notice: Refer to Fastener Notice.

6. Install the fuel tank strap bolts (2).

Tighten the bolts to 48 N.m (35 lb ft).

7. Remove the jack from the fuel tank.




8. Position the fuel tank shield (3) to the fuel tank (1).
9. Install the push pins (2).




10. Install the two parts of the EVAP fresh air hose at the splice.
11. Raise the exhaust system to the original position.
12. Install the exhaust system to the exhaust pipe hangers.




13. Connect the fuel feed (4), the fuel return (2) and the evaporative emission (EVAP) (3) pipes at the fuel filter area. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




14. Install the fuel tank filler hose to the fuel tank.




15. Fully seat the filler hose (4) on the fuel tank port (2).
16. Ensure that the clamp (1) is properly located on the tank port between the bead (5) and the tank (3).

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

17. Lower the vehicle.
18. Add fuel and install the fuel fill cap.
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LY7) (Service and Repair).
20. Inspect the fuel system for leaks by performing the following steps:

1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.

21. Install fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).