Fuel Tank Replacement

Fuel Tank Replacement (With AWD)

Removal Procedure

Warning:
Refer to Gasoline/Gasoline Vapors Warning Service Precautions.


Warning

Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

Warning

Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

For Vehicles equipped with OnStar(R) (UE1) with Back Up Battery:

The Back Up Battery is a redundant power supply to allow limited OnStar(R) functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar(R)module). Do not disconnect the main vehicle battery or remove the OnStar(R) fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar(R) module in any way while the ignition is On or with RAP activated may cause activation of the OnStar(R) Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.

1. Turn the ignition OFF.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.

4. Drain the fuel tank. Refer to Fuel Tank Draining ProceduresFuel Tank Draining Procedures.

5. Remove the propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.

6. Remove the exhaust system. Refer to Exhaust Muffler Replacement (Single) Exhaust Muffler Replacement (Single)Exhaust Muffler Replacement (LFX) Exhaust Muffler Replacement (LFX)

7. Remove the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement .





8. Disconnect the fuel tank fuel pump module wiring harness (2).

9. Unclip the fuel tank module wiring harness from the chassis (1).





Warning

Do not breathe the air through the EVAP component tubes or hoses. The fuel vapors inside the EVAP components may cause personal injury.

10. Disconnect the fuel tank filler vent pipe from the fuel tank filler vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures.

11. Disconnect the fuel tank filler tube (2) from the fuel tank.





12. Disconnect the evaporative emission purge and fuel feed pipes (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.

13. Disconnect the fuel pressure sensor harness connector (2).

14. Disconnect the wiring harness connector from the fuel pipe.

15. Position a suitable hydraulic lift below the fuel tank.





16. Remove both fuel tank strap fasteners (3).

17. Remove both fuel tank straps (2) from the fuel tank (1).

Warning

To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack.

Caution:
When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result.

Note:
carefully maneuver the fuel tank past the exhaust system.

18. With the aid of an assistant, lower the hydraulic lift to remove the fuel tank from the vehicle.

19. Remove the fuel tank from the hydraulic lift.

Installation Procedure

1. If replacing the fuel tank transfer the following components.





* The evaporative emission canister (2). Refer to Evaporative Emission Canister Replacement (With AWD) Evaporative Emission Canister ReplacementEvaporative Emission Canister Replacement (With FWD) Evaporative Emission Canister Replacement.





* The evaporative emission canister purge pipe (1). Refer to Evaporative Emission Canister Purge Pipe Replacement (With AWD) Service and RepairEvaporative Emission Canister Purge Pipe Replacement (With FWD)





* The fuel tank feed pipe (2). Refer to Fuel Feed Pipe Replacement (With AWD at Tank) Fuel Feed Pipe Replacement (With AWD at Tank)Fuel Feed Pipe Replacement (LFW or LFX) Fuel Feed Pipe Replacement (LFW or LFX)





* The sender assembly (1). Refer to Fuel Sender Assembly Replacement (With AWD) Service and Repair





* The tank fuel pump module (1). Refer to Fuel Tank Fuel Pump Module Replacement (With AWD) Service and RepairFuel Tank Fuel Pump Module Replacement (LFW or LFX) Service and Repair

* The fuel tank wiring harness.





Note:
carefully maneuver the fuel tank past the exhaust system.

2. With the aid of an assistant, position the fuel tank on a hydraulic lift and raise into vehicle position.

Caution:
Refer to Fastener Caution Fastener Caution.

3. Install both fuel tank straps (2) to the fuel tank (1) and tighten the fasteners (3) to 27 Nm (20 lb ft).

4. Remove the hydraulic lift from the fuel tank.





5. Connect the evaporative emission purge and fuel pipes (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.

6. Connect the fuel pressure sensor harness connector (2).





7. Install the fuel tank filler tube (2) and tighten the clamp (1).

8. Connect the fuel tank filler vent pipe to the fuel tank filler vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures.





9. Connect the fuel tank fuel pump module wiring harness (2).

10. Clip the fuel tank module wiring harness to the chassis (1).

11. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement .

12. Install the exhaust system. Refer to Exhaust Muffler Replacement (Single) Exhaust Muffler Replacement (Single)Exhaust Muffler Replacement (LFX) Exhaust Muffler Replacement (LFX).

13. Install the propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.

14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

15. Refuel the fuel tank.