Fuel Tank Replacement
REMOVAL PROCEDURENOTE: Refer to Cover and Plug Openings Notice in Service Precautions.
IMPORTANT: Always maintain cleanliness when servicing the fuel system components.
1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
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 and return pipes at the fuel filter and fuel filter area. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
7. Disconnect 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. Separate the two halves of the EVAP fresh air hose at the splice.
10. Remove the fuel tank shield push pins (2).
11. Remove the fuel tank shield (3).
NOTE: Do not bend the fuel tank straps as this may damage the straps.
12. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts (2) from the fuel tank straps (3).
13. Remove the fuel tank from the vehicle.
14. Place the fuel tank in a suitable work area.
15. If the fuel tank is not being replaced, go to the Fuel Tank Installation Procedure.
16. Remove the EVAP canister.
17. Remove the fuel feed, fuel return, and EVAP pipe assemblies and the insulator clips from the fuel tank. Refer to Fuel Hose/Pipes Replacement - Filter to Tank and Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank.
18. 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.
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.
2. Install the fuel teed, the fuel return, and the EVAP pipe assemblies and the insulator clips. Refer to Fuel Hose/Pipes Replacement - Filter to Tank and Evaporative Emission (EVAP) Hoses/Pipes Replacement - Canister/Fuel Tank.
3. Install the EVAP canister.
4. With the aid of an assistant, position and support the fuel tank.
NOTE: Refer to Fastener Notice in Service Precautions.
5. Install the bolts (2) to the fuel tank retaining straps (3).
Tighten
Tighten the bolts to 48 N.m (35 lb ft).
6. Position the tank shield (3), and install the three push nuts (2).
7. Connect the quick-connect fittings at the fuel filter and fuel filter area.
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.
8. Connect the EVAP pipe at the front of the fuel tank.
9. Connect the fuel tank filler hose to the fuel tank.
10. Connect the two parts of the EVAP fresh air hose at the splice.
11. Fully seat the tiller hose (4) on the fuel tank port (2).
12. Make sure clamp (1) is properly located on tank port between the bead (5) and tank (3).
Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).
13. Install the rubber 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:
18.1. Turn ON the ignition for 2 seconds.
18.2. Turn OFF the ignition for 10 seconds.
18.3. Turn ON the ignition.
18.4. Inspect for fuel leaks.