Fuel Tank Replacement
Fuel Tank Replacement
Special Tools
EN-48279 - Main Fuel Pump Locking Ring Remover/Installer
For equivalent regional tools, refer to Special Tools (Diagnostic Tools) Tools and Equipment.
Removal Procedure
Warning:
Refer to Gasoline/Gasoline Vapors Warning Service Precautions.
Warning
Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.
Warning
Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar(R) (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited OnStar(R) functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar(R)module). Do not disconnect the main vehicle battery or remove the OnStar(R) fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar(R) module in any way while the ignition is On or with RAP activated may cause activation of the OnStar(R) Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.
1. Turn the ignition OFF.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedures.
4. Drain the fuel tank. Refer to Fuel Tank Draining Procedures.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
6. Remove the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement Service and Repair.
7. Disconnect the fuel tank fuel pump module wiring harness (2).
8. Unclip the fuel tank module wiring harness from the chassis (1).
Warning
Do not breathe the air through the EVAP component tubes or hoses. The fuel vapors inside the EVAP components may cause personal injury.
9. Disconnect the fuel tank filler vent pipe quick connector (1) from the fuel tank filler vent pipe. Refer to Plastic Collar Quick Connect Fitting Service Procedures.
10. Remove the fuel tank filler hose fastener (3).
11. Remove the fuel tank filler hose (4).
12. Disconnect the evaporative emission front pipe quick connector from the evaporative emission front pipe (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.
13. Disconnect the fuel feed front pipe quick connector from the fuel feed front pipe (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures.
14. Disconnect the wiring harness plug from the fuel pipe.
15. Position a suitable hydraulic lift below the fuel tank.
16. Remove both fuel tank strap fasteners (1).
17. Remove both fuel tank straps from the fuel tank (2).
Warning
To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack.
Caution:
When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result.
18. With the aid of an assistant, lower the hydraulic lift to remove the fuel tank from the vehicle.
19. Remove the fuel tank from the hydraulic lift.
Disassembly Procedure
1. Disconnect and unclip the fuel tank fuel pump module wiring harness from the fuel tank pump module (2), fuel tank pressure sensor (3) and evaporative emission canister (4).
2. Disconnect the fuel tank feed pipe from the fuel tank fuel pump module (1) and fuel tank retainer. Refer to Plastic Collar Quick Connect Fitting Service Procedures.
3. Remove the fuel tank vent pipe (1) from the fuel tank (2) and evaporative canister (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures
4. Disengage the locking tab (1), while lifting the evaporative emission canister (3) away from the fuel tank (2).
Note:
Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
5. Install the EN-48279 - remover/installer(1) to the fuel pump module lock ring (2).
6. Using the EN-48279 - remover/installerand a long breaker-bar, rotate the fuel pump module lock ring (1) in a counterclockwise direction in order to unlock the fuel pump module lock ring.
7. Remove the fuel tank fuel pump module (2).
Note:
Lift the fuel tank fuel pump module up slightly.
8. Remove and discard the fuel tank fuel pump module O-ring seal (3).
9. Remove the fuel tank shield fasteners (1).
10. Remove the fuel tank shield (1).
Assembly Procedure
1. Install the fuel tank shield (1).
2. Install the fuel tank shield fasteners (1).
3. Install a NEW fuel tank fuel pump module O-ring seal (3).
4. Install the fuel tank fuel pump module (2).
5. Install the fuel pump module lock ring (1).
Note:
Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
6. Using the EN-48279 - remover/installer(1) and a long breaker-bar, rotate the fuel pump module lock ring in a clockwise direction in order to lock the fuel pump module lock ring (2).
7. Position the evaporative emission canister (3) into the retaining feature of the fuel tank (2).
8. Ensure that the retaining tab (1) on the evaporative emission canister lock into place.
9. Install the fuel tank vent pipe (1) to the fuel tank (2) and evaporative canister (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures
10. Connect the fuel tank feed pipe to the fuel tank fuel pump module (1) and fuel tank retainer. Refer to Plastic Collar Quick Connect Fitting Service Procedures.
11. Connect and clip the fuel tank fuel pump module wiring harness to the fuel tank pump module (2), fuel tank pressure sensor (3) and evaporative emission canister (4).
Installation Procedure
Caution:
Refer to Fastener Caution Fastener Caution.
1. Install the fuel tank to the hydraulic lift.
2. With the aid of an assistant, position the fuel tank to the vehicle.
Caution:
Refer to Fastener Caution Fastener Caution.
3. Install both fuel tank straps to the fuel tank (2) and tighten the fasteners to 27 Nm 20 lb ft.
4. Remove the hydraulic lift from the fuel tank.
5. Connect the fuel feed front pipe quick connector to the fuel feed front pipe (2). Refer to Plastic Collar Quick Connect Fitting Service Procedures.
6. Connect the evaporative emission front pipe quick connector to the evaporative emission front pipe (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.
7. Connect the wiring harness to the fuel feed pipe.
8. Install the fuel tank filler hose (4).
9. Install the fuel tank filler hose fastener (3) and tighten to 4 Nm (35 lb in).
10. Connect the fuel tank filler vent pipe quick connector (1) to the fuel tank filler vent pipe. Refer to Plastic Collar Quick Connect Fitting Service Procedures.
11. Connect the fuel tank fuel pump module wiring harness (2).
12. Clip the fuel tank module wiring harness to the chassis (1).
13. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement Service and Repair.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.