Removal and Replacement

FUEL TANK REPLACEMENT (TRAILBLAZER, ENVOY, BRAVADA, RAINIER)

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Raise the vehicle. Refer to Vehicle Lifting.
3. Remove the frame brace.
4. Remove the fuel tank shield, if equipped.
5. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
6. Disconnect the fuel tank pressure sensor electrical connector (3).
7. Disconnect the evaporative emission (EVAP) vent valve electrical connector (2).




8. Disconnect the EVAP vapor pipe (4) from the EVAP canister (3).
9. Disconnect the EVAP vent valve pipe (2) from the EVAP canister (3).




10. Disconnect the fuel return pipe and the fuel feed pipe (1).
11. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.




12. With the aid of an assistant, support the fuel tank.

NOTE: Refer to Damage to Fuel Tank Straps Notice in Service Precautions.

13. Remove the fuel tank strap attaching bolts.
14. Remove the fuel tank straps.
15. Carefully lower the fuel tank.
16. Disconnect the fuel sender electrical connector.
17. Remove the fuel tank.
18. Place the fuel tank in a suitable work area.
19. If the fuel tank is not being replaced, go to the Installation Procedure.


DISASSEMBLY PROCEDURE




1. Remove the EVAP vent valve (1).
2. Remove the fuel filter (7).
3. Disconnect the fuel feed and return pipes from the fuel sender (4).
4. Remove the fuel feed and return pipes from the retaining clip (6).
5. Remove the EVAP vent valve pipe.
6. Disconnect the EVAP vapor pipe from the fill limiter vent valve (3), and the front and rear rollover valves (2, 5).
7. Remove the EVAP vapor pipes.
8. Remove the fuel sender assembly (4) from the fuel tank.

ASSEMBLY PROCEDURE




1. Install the fuel sender assembly (4) to the fuel tank.
2. Connect the EVAP vapor pipe to the fill limiter vent valve (3) and the front and rear rollover valve (2, 5).
3. Install the EVAP vent valve pipe.
4. Connect the fuel feed and return pipes to the fuel sender (4).
5. Install the fuel feed and return pipes to the retaining clip (6).
6. Install the fuel filter (7).
7. Install the EVAP vent valve (1).

INSTALLATION PROCEDURE




1. With the aid of an assistant, position and support the fuel tank.
2. Connect the fuel sender electrical connector.
3. Install the fuel tank straps.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the fuel tank strap attaching bolts.

Tighten
Tighten the bolts to 32 N.m (24 lb ft).




5. Remove the caps from the fuel and EVAP pipes.
6. Connect the fuel return pipe and the fuel feed pipe (1).




7. Connect the EVAP vent valve pipe (2) to the EVAP canister (3).
8. Connect the EVAP vapor pipe (4) to the EVAP canister (3).




9. Connect the fuel pressure sensor electrical connector (3).
10. Connect the EVAP vent valve electrical connector (2).




11. Connect the fuel till hose (2) to the fuel tank.

Tighten
Tighten the fuel fill hose clamp (1) to 2.5 N.m (22 lb in).

12. Lower the vehicle.
13. Refill the fuel tank.
14. Install the fuel filler cap.
15. Connect the negative battery cable.
16. Raise the vehicle. Refer to Vehicle Lifting.
17. Inspect for leaks.
17.1. Turn ON the ignition, with the engine OFF for 10 seconds.
17.2. Turn OFF the ignition for 10 seconds.
17.3. Turn ON the ignition, with the engine OFF.
17.4. Inspect for fuel leaks.
18. Install the fuel tank shield, if equipped.
19. Install the frame brace.
20. Lower the vehicle.