Removal and Replacement

FUEL TANK REPLACEMENT

REMOVAL PROCEDURE
1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.

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 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 feed, the fuel return and the evaporative emission (EVAP) pipes quick-connect fittings at the fuel tank.
7. Remove the exhaust pipe hangers in order to allow the exhaust system to drop slightly.




8. Separate the 2 halves of the EVAP fresh air hose at the splice.




9. Remove the fuel tank shield push pins (2) and the fuel tank shield (3).




10. Support the fuel tank with a suitable jack.
11. Remove the fuel tank strap bolts (2).

NOTE: Do not bend the fuel tank straps as this may damage the straps.

12. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.




13. Remove the EVAP canister.
14. Remove the fuel feed, the fuel return, and the EVAP pipe assemblies and the insulator clips from the fuel tank.
15. Remove the insulator pad from the fuel tank. Note the location of the insulator pad for the installation.

INSTALLATION PROCEDURE
1. Install the insulator pad on the fuel tank.




2. Install the fuel feed, the fuel return, and the EVAP pipe assemblies and the insulator clips.

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.

3. Install the EVAP canister.




4. Install the fuel tank to a suitable jack.
5. Raise the fuel tank to the original position.
6. Install the fuel tank strap bolts (2).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the bolts to 48 N.m (35 lb ft).




7. Position the tank shield (3), and install the push pins (2).




8. Connect the fuel feed, the fuel return and the EVAP pipes quick-connect fittings at the fuel tank.




9. Install the 2 halves of the EVAP fresh air hose at the splice.




10. Install the fuel tank filler hose to the fuel tank.




11. Fully seat the filler hose (4) on fuel tank port (2).
12. ensure the clamp (1) is properly located on tank port between the bead (5) and the tank (3).

Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).

13. Raise the exhaust to the original and install the exhaust pipe hangers.
14. Lower the vehicle.
15. Install the fuel sender assembly.
16. Add fuel and install the fuel filler pipe cap.
17. Connect the negative battery cable.
18. Inspect for fuel leaks using the following procedure:
1. Turn ON the ignition, for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.