Removal and Replacement
REMOVAL PROCEDURE1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Release
NOTE: Refer to Cover and Plug Openings Notice in Service Precautions.
IMPORTANT: Always maintain cleanliness when servicing the fuel system components.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure
3. Raise and support the vehicle. Refer to Vehicle Lifting.
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 recirculating pipe from the fuel filler pipe.
7. Disconnect the fuel feed, the fuel return and the evaporative emission (EVAP) pipes at the fuel filter area.
8. Separate the two halves of the EVAP fresh air hose at the splice.
9. Support the exhaust system.
10. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
11. Remove the fuel tank shield push pins (2).
12. Remove the fuel tank shield (3).
13. Support the fuel tank with a suitable jack.
NOTE: Do not bend the fuel tank straps as this may damage the straps.
14. Remove the fuel tank strap bolts (2).
15. Remove the fuel tank (1) from the vehicle.
16. Place the fuel tank in a suitable work area.
17. Remove the fuel feed and the fuel return pipes (2) from the fuel tank. Note the location of the fuel pipes for installation.
18. Release the EVAP canister retaining strap and remove the EVAP canister (1) from the fuel tank.
IMPORTANT: Replace the EVAP canister retaining strap when removing the EVAP canister.
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 as noted during removal.
2. Install the EVAP canister (1) to the fuel tank.
3. Install a new EVAP canister retaining strap.
4. Install the fuel feed and the fuel return pipes (2) as noted during removal.
NOTE:
- 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.
1. Install the fuel tank to a suitable jack.
2. Raise the fuel tank (1) to the original position.
3. Install the fuel tank strap bolts (2).
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the bolts to 48 N.m (35 lb ft).
4. Remove the jack from the fuel tank.
5. Position the fuel tank shield (3) to the fuel tank (1).
6. Install the push pins (2).
7. Raise the exhaust system to the original position.
8. Install the exhaust system to the exhaust pipe hangers.
9. Install the two parts of the EVAP fresh air hose at the splice.
10. Connect the EVAP pipe, the fuel feed and the fuel return pipes at the front of the fuel tank.
11. Connect the fuel recirculating pipe to the fuel filler pipe.
12. Install the fuel tank filler hose to the fuel tank.
13. Fully seat the filler hose (4) on the fuel tank port (2).
14. Ensure the clamp (1) is properly located on the tank port between the bead (5) and the tank (3).
Tighten
Tighten the hose clamp to 2.5 N.m (22 lb in).
15. Lower the vehicle.
16. Install the fuel sender assembly.
17. Add fuel and install the fuel fill cap.
18. Connect the negative battery cable.
19. Inspect the fuel system for leaks by performing the following steps:
19.1. Turn ON the ignition for 2 seconds.
19.2. Turn OFF the ignition for 10 seconds.
19.3. Turn ON the ignition.
19.4. Inspect for fuel leaks.
20. Install fuel injector sight shield.