Fuel Tank Replacement - Left Side
Fuel Tank Replacement - Left Side
Special Tools
J 37088-A Fuel Line Disconnect Tool
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LS3) (Battery Negative Cable Disconnection and Connection) Battery Negative Cable Disconnection and Connection (LS7 or LS9) (Battery Negative Cable Disconnection and Connection).
2. Drain the fuel tank. Refer to Fuel Tank Draining (Procedures).
3. Remove the left rear wheelhouse panel. Refer to Rear Wheelhouse Panel Liner Replacement ([1][2]Rear Wheelhouse Panel Liner Replacement).
4. Remove both mufflers. Refer to Exhaust Muffler Replacement - Left Side (Exhaust Muffler Replacement - Left Side) and Exhaust Muffler Replacement - Right Side (Exhaust Muffler Replacement - Right Side).
5. If automatic transmission, remove the driveline support assembly. Refer to Driveline Support Assembly Replacement (Driveline Support Assembly Replacement).
6. Disconnect the fuel fill hose and recirc line from the fill pipe.
7. Disconnect the fuel pump jumper harness connector.
8. Disconnect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
9. Cap the fuel pipes to prevent fuel system contamination.
10. Loosen the fuel tank strap in order to drop the tank approximately 1 inch.
11. Disengage the crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.
Note: The crossover tube CPA is released when the latch disengages from the tank connection groove.
12. Rotate the collar counterclockwise to disengage.
13. Disconnect the crossover tube (5) from the left fuel tank.
Note: Take care not to disturb the internal O-rings in the fuel tank connections.
14. Disconnect the evaporative emission (EVAP) crossover pipe (2) quick connect fitting at the left fuel tank.
15. Cap the EVAP pipes (1 and 3) to prevent system contamination.
16. Remove the fuel tank strap mount bolts.
17. Remove the fuel tank strap from the vehicle.
18. Remove the fuel tank.
19. If the fuel pump sending unit is being removed and installed into the new tank, refer to Fuel Tank Fuel Pump Module Replacement - Left Side (LS9) (Fuel Tank Fuel Pump Module Replacement - Left Side) Fuel Tank Fuel Pump Module Replacement - Left Side (LS3, LS7) (Fuel Tank Fuel Pump Module Replacement - Left Side)
Installation Procedure
1. If replacing the tank with LS9 engine, install a NEW heat shield (1) to the left side tank by removing the backing from the adhesive.
2. Press firmly to ensure full contact and adhesion onto the tank.
3. Install the fuel tank.
4. Install the fuel tank strap to the vehicle.
5. Install the fuel tank strap bolts loosely leaving the tank hanging approximately one inch.
6. Remove the caps from the EVAP pipes (1 and 3).
7. Connect the EVAP crossover pipe (2) quick connect fitting at the left fuel tank.
8. Lubricate the crossover tube to fuel tank connection O-rings (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
Note: Note the location of the T-shaped alignment feature (5) between the jet pump feed/return pipes connector.
9. Lubricate the crossover tube O-ring mating surfaces (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
Note:
* Note the T-shaped alignment feature on the crossover tube.
* The crossover tube will not fully seat into the fuel tank if the jet pump lines are misaligned.
10. Connect the crossover tube to the left fuel tank using the features previously noted.
Note: The crossover tube collar tangs will not latch if misalignment exists.
11. Rotate the crossover tube collar (3) clockwise to engage the tangs.
12. Rotate the crossover tube CPA retainer counterclockwise past the collar latching tang and push the tab (1) into the locked position.
Note: If the CPA retainer is locked into position, the crossover tube collar will not rotate.
13. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.
Caution: Refer to Fastener Caution (Fastener Caution).
14. Tighten the fuel tank strap bolts.
Tighten the bolts to 25 Nm (18 lb in).
15. Remove the cap from the fuel pipes.
16. Connect the fuel feed pipe (4) at the rear of the left fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
17. Connect the fuel pump jumper harness connector.
18. Connect the fuel fill hose and recirc line to the fill tube.
Tighten the clamp to 4 Nm (35 lb in).
19. If automatic transmission, install the driveline support assembly. Refer to Driveline Support Assembly Replacement (Driveline Support Assembly Replacement).
20. Install both mufflers. Refer to Exhaust Muffler Replacement - Left Side (Exhaust Muffler Replacement - Left Side) and Exhaust Muffler Replacement - Right Side (Exhaust Muffler Replacement - Right Side).
21. Install the left rear wheelhouse panel. Refer to Rear Wheelhouse Panel Liner Replacement ([1][2]Rear Wheelhouse Panel Liner Replacement).
22. Lower the vehicle.
23. Refuel the fuel tank.
24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LS3) (Battery Negative Cable Disconnection and Connection) Battery Negative Cable Disconnection and Connection (LS7 or LS9) (Battery Negative Cable Disconnection and Connection).
25. Perform the following procedure in order to test for leaks:
1. Turn ON the ignition switch for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.
* Fuel pump on: 400 kPa (58 psi)
* Fuel pump off: 359 kPa (52 psi)