Removal and Replacement
REMOVAL PROCEDURECAUTION: Provide additional support when a vehicle is on a hoist:
^ Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
^ Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
NOTE:
^ Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.
^ Do not bend the fuel tank straps as this may damage the straps.
^ 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.
^ Refer to Cover and Plug Openings Notice in Service Precautions.
IMPORTANT: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.
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 tank filler hose clamp (1) at the fuel tank (3).
5. Remove the fuel tank filler hose from the fuel tank.
6. Disconnect the quick-connect fittings at the fuel tank.
7. Disconnect the evaporative emission (EVAP) pipe from the connection at the front of the fuel tank.
8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
9. Support the fuel tank with a suitable jack.
10. Support the fuel tank strap bolts.
11. Lower the fuel tank to access the EVAP connections.
12. Disconnect the EVAP pipes (4) from the rear of the fuel tank.
13. Disconnect the EVAP pipe (2) from the fuel limiter vent valve.
14. Disconnect the fuel filler neck EVAP pipe (3) at the rear of the fuel tank.
15. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
16. Remove the fuel feed, fuel return, EVAP pipe assemblies and the insulator clips from the fuel tank.
17. Remove the EVAP canister from the fuel tank.
18. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.
INSTALLATION PROCEDURE
1. Install the insulator pads on the fuel tank.
2. Install the EVAP canister to the fuel tank.
3. Connect the fuel feed, fuel return, EVAP pipe assemblies and install the insulator clips.
4. Install the fuel tank to a suitable jack.
5. Connect the EVAP pipes (4) to the rear of the fuel tank.
6. Connect the EVAP pipe (2) to the fuel limiter vent valve.
7. Connect the fuel filler EVAP pipe (3) at the rear of the fuel tank.
8. Raise the fuel tank to the original position.
NOTE: Refer to Fastener Notice in Service Precautions.
9. Install the fuel tank retaining strap bolts.
Tighten
Tighten the front fuel tank retaining strap bolts to 47 N.m (35 lb ft).
10. Remove the jack from the fuel tank.
11. Connect the quick-connect fittings at the fuel tank.
12. Connect the EVAP pipe at the front of the fuel tank.
13. Install the fuel tank filler hose to the fuel tank.
14. Inspect and make sure that the filler hose (4) is fully seated on fuel tank port (2).
15. Make sure the clamp (1) is properly located on tank port between the bead (5) and the tank (3).
Tighten
Tighten the hose clamp to 2.5 N.m (22 lb in).
16. Install the exhaust pipe to the exhaust hangers.
17. Inspect the fuel and EVAP pipes making sure they were not kinked or damaged during removal and installation.
18. Lower the vehicle.
19. Install the fuel sender assembly.
20. Add fuel and install the fuel fill cap.
21. Connect the negative battery cable.
22. Inspect for leaks.
22.1. Turn ON the ignition for 2 seconds.
22.2. Turn OFF the ignition for 10 seconds.
22.3. Turn ON the ignition.
22.4. Inspect for fuel leaks.
23. Install fuel injection sight shield.