Fuel Tank Replacement (Left)

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 34730-1A Fuel Pressure Gauge
^ J 37088-A Tool Set, Fuel Line Quick Connect Separator

CAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure.
3. Drain the fuel tanks.
4. Raise the vehicle.
5. Remove the left rear tire and wheel.
6. Remove the left muffler (auto trans equipped vehicles only).
7. Remove the left rear wheelhouse panel.
8. Disconnect the fuel fill hose (3) and the vent hose (4).




9. Disconnect the [1][2]EVAP pipe (2) from the fuel pressure sensor (3).




10. Remove the fuel tank shield mount nut (2).
11. Remove the fuel tank shield mount bolt (1).
12. Remove the fuel tank shield (3).




13. Disconnect the fuel sender electrical connector.
14. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
15. Disconnect the fuel sender fuel feed pipe (1) (jet pump to left tank), the fuel return rear pipe (2), and the fuel feed rear pipe (3) at the fuel sender.
16. Cap the fuel pipes in order to prevent possible fuel system contamination.




17. Disconnect the tank crossover hose (5).
18. Disconnect the fuel tank vapor pipe (2) quick-connect fitting at the left fuel tank vapor pipe (1).
19. Cap the fuel tank vapor pipe in order to prevent possible contamination.




20. Remove the fuel tank strap mount bolts.
21. Remove the fuel tank strap (3).




22. Remove the fuel tank.

INSTALLATION PROCEDURE





IMPORTANT: Always replace the fuel system hose clamps with the original equipment or parts that meet the GM specifications for those parts when replacing the clamps.

1. Install the fuel tank.




2. Install the fuel tank strap (3).

NOTE: Refer to the Fastener Notice in Cautions and Notices.

3. Install the fuel tank strap bolts (1 2, 4).

Tighten
3.1. Tighten bolt (2) to 25 N.m (18 lb ft).
3.2. Tighten bolt (1) to 25 N.m (18 lb ft).
3.3. Tighten the remaining bolts (4) to 25 N.m (18 lb ft).




4. Remove the cap from the fuel tank vapor pipe.
5. Connect the fuel tank vapor pipe (2) quick-connect fitting at the left fuel tank vapor pipe (1).
6. Install the tank crossover hose (5).
7. Push the clamp outboard against the fuel tank keeping the clamp parallel with the white stripe on the tank crossover hose.

Tighten
Tighten the tank crossover hose clamp to 4 N.m (35 lb in).




8. Remove the caps from the fuel pipes.
9. Connect the fuel sender fuel feed pipe (1) (jet pump to left tank), the fuel return rear pipe (2), and the fuel feed rear pipe (3).
10. Connect the fuel sender electrical connector.




11. Install the fuel tank shield (3).
12. Install the fuel tank shield mount bolt (1).
13. Install the fuel tank shield mount nut (2).

Tighten
^ Tighten the fuel tank shield mount bolt to 25 N.m (18 lb ft).
^ Tighten the fuel tank shield mount nut to 25 N.m (18 lb ft).




14. Connect the [1][2]EVAP pipe (2) to the fuel pressure sensor (3).




15. Connect the fuel fill hose (3) and the vent hose (4).

Tighten
Tighten the fuel fill hose clamp and the vent hose clamp to 4 N.m (35 lb in).

16. Install the left rear wheelhouse panel.
17. Install the left muffler (auto trans equipped vehicles only).
18. Install the left rear tire and wheel.
19. Lower the vehicle.
20. Refill the fuel system.
21. Connect the negative battery cable.
22. Inspect for leaks.
22.1. Turn the ignition switch ON for 2 seconds.
22.2. Turn the ignition switch OFF for 10 seconds.
22.3. Turn the ignition switch ON.
22.4. Check for fuel leaks.
23. Program the transmitters. Refer to Transmitter Programming/Synchronization in keyless Entry.
24. Perform the idle learn procedure. Refer to PCM Idle Learn Procedure.