Fuel Tank Assembly

Fuel Filler Hoses:

Descriptive:

Removal Procedure

WARNING: In order to avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

NOTE: If nylon the fuel feed or the return pipes become kinked and cannot be straightened, they must be replaced. 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 Release.
2. Drain the fuel tank.
3. Raise the vehicle.
4. Remove the fuel tank filler EVAP hose from the fuel tank.
5. Remove the fuel tank filler hose from the fuel tank.
6. Remove the quick-connect fittings at the fuel tank.
7. Remove the 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. Remove the exhaust pipe heat shield bolts and the exhaust pipe heat shield.
10. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.
11. Lower the fuel tank enough in order to disconnect the fuel sender electrical connector and remove the fuel sender retaining clips.
12. Remove the EVAP pipe to the rear of the fuel tank.
13. Remove the EVAP pipe to the fuel sender assembly.
14. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
15. If the fuel tank is not being replaced, go to Installation Procedure.
16. Remove the fuel sender assembly.
17. Remove the retaining clip from the EVAP pipe. Note the position of the retaining clip for installation.
18. Remove the EVAP pipe from the insulator clips. Note the position of the EVAP pipe for installation.
19. Remove the quick-connect fittings at the fuel sender.
20. Remove the fuel feed and fuel return pipe assemblies and the insulator clips from the fuel tank.
21. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.

Installation Procedure

NOTE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. General Motors will call out those fasteners that require a replacement after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant.

CAUTION: UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

1. Install the insulator pads on the fuel tank.
2. Install the insulator clips.
3. Install the quick-connect fittings at the fuel sender.
4. Install the fuel feed and fuel return pipe assemblies.
5. Position the EVAP pipe on the insulator clips as noted during disassembly.
6. Install the retaining clip on the EVAP pipe.
7. Install the fuel sender assembly.
8. With the aid of an assistant, position and support the fuel tank.
9. Install the EVAP pipe to the rear of the fuel tank.
10. Install the EVAP pipe to the fuel sender assembly.
11. Install the fuel sender electrical connector and the fuel sender retaining clips.
12. Install the fuel tank retaining strap attaching bolts (4). Tighten the front and rear fuel tank retaining strap bolts (4) to 47 Nm (35 lb ft).
13. Install the quick-connect fittings.
14. Install the EVAP pipe at the front of the fuel tank.
15. Install the fuel tank filler EVAP pipe to the fuel tank. Tighten the fuel tank filler EVAP pipe hose clamp to 2.5 Nm (22 lb in).
16. Install the fuel tank filler pipe to the fuel tank. Tighten the fuel tank filler pipe hose clamp to 2.5 Nm (22 lb in).
17. Install the heat shield and the heat shield attaching screws.
18. Install the rubber exhaust pipe hangers.
19. Lower the vehicle.
20. Add fuel and install the fuel tank filler pipe cap.
21. Install the negative battery cable.
22. Inspect for leaks.

22.1. Inspect turn the ignition switch to the ON position for 2 seconds.
22.2. Turn the ignition switch to the OFF for 10 seconds.
22.3. Turn the ignition switch to the ON position again.
22.4. Check for fuel leaks