Removal

Removal Procedure

WARNING: 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.

Notice: 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.

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

Notice:
- 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 Fluroelastomer or GM 6163M on the hose.

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Important: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.


Important: Always maintain cleanliness when servicing fuel system components.


1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Release Procedure.
2. Drain the fuel tank.
3. Remove the fuel sender assembly.
4. Raise the vehicle.




5. Loosen the fuel tank filler hose clamp (1) at the fuel tank (3).




6. Remove the fuel tank filler hose from the fuel tank.
7. Remove the quick-connect fittings at the fuel tank. Refer to Fuel Line Coupler Service (Metal Collar).




8. Remove the EVAP pipe from the connection at the front of the fuel tank.
9. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.



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. Disconnect the EVAP (3) pipes (4) from the rear of the fuel tank.
12. Disconnect the EVAP pipe from the fuel limiter vent valve.
13. Disconnect the fuel filler neck EVAP pipe at the rear of the fuel tank.
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 Fuel Tank Installation Procedure.




16. Remove the fuel feed, fuel return, and EVAP pipe assemblies and the insulator clips from the fuel tank.
17. Remove the fuel limiter vent valve from the fuel tank.




18. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.