Fuel Tank Replacement Right

Tools Required

Caution: 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.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
3. Drain the fuel tanks. Refer to Fuel Tank Draining .

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the right rear tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Remove the fuel tank shield mount nut (3).
7. Remove the fuel tank shield mount bolt (2).
8. Remove the fuel tank shield (1).
9. Remove the right muffler (auto trans equipped vehicles only). Refer to Muffler Replacement in Engine Exhaust.



10. Disconnect the fuel sender electrical connector.
11. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
12. Disconnect the auxiliary fuel return rear pipe (1) from the jet pump to the left tank and the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump at the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
13. Cap the fuel pipes in order to prevent possible fuel system contamination.



14. Remove the right rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
15. Remove the EVAP canister access cover.



16. Disconnect the FLVV hose (1) at the EVAP canister (2).
17. Disconnect the fuel pressure sensor electrical connector.



18. Disconnect the tank crossover hose (5).
19. Disconnect the EVAP pipe (2) quick connect fitting at the right fuel tank EVAP pipe (3).
20. Cap the EVAP pipe in order to prevent possible contamination.



21. Remove the fuel tank strap mount bolts (1,2,4).
22. Remove the fuel tank strap (3).



23. Remove the fuel tank.

Important: Always replace the fuel system hose clamps with the original equipment or parts that meet the GM specifications for those parts when replacing the clamps.

1. Install the fuel tank.



2. Install the fuel tank strap (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the fuel tank strap bolts (1,2,4).

Tighten

1. Tighten bolt (2) to 25 N·m (18 lb ft).
2. Tighten bolt (1) to 25 N·m (18 lb ft).
3. Tighten the remaining bolts (4) to 25 N·m (18 lb ft).



4. Remove the cap from the EVAP pipe.
5. Connect the EVAP pipe (2) quick connect fitting at the right fuel tank EVAP pipe (3).
6. Connect the tank crossover hose (5).
7. Push the clamp (4) outboard against the fuel tank keeping the clamp parallel with the white stripe on the tank crossover hose.

Tighten
Tighten the tank crossover hose clamp to 4 N·m (35 lb in).




8. Connect the fuel pressure sensor electrical connector.
9. Connect the FLVV hose (1) at the EVAP canister (2).



10. Install the EVAP canister access cover.
11. Install the right rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.



12. Remove the caps from the fuel pipes.
13. Connect the auxiliary fuel return rear pipe (1) from the jet pump to the left tank and the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump. Refer to Plastic Collar Quick Connect Fitting Service .
14. Connect the fuel sender electrical connector.
15. Install the right muffler (auto trans equipped vehicles only). Refer to Muffler Replacement in Engine Exhaust.



16. Install the fuel tank shield (1).
17. Install the fuel tank shield mount bolt (2).
18. Install the fuel tank shield mount nut (3).

Tighten

•	Tighten the fuel tank shield mount bolt to 25 N·m (18 lb ft).

•	Tighten the fuel tank shield mount nut to 12 N·m (106 lb in).

19. Install the right rear tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
20. Lower the vehicle.
21. Refill the fuel system.
22. Connect the negative battery cable.
23. Inspect for leaks.

23.1.

Turn the ignition switch ON for 2 seconds.

23.2.

Turn the ignition switch OFF for 10 seconds.

23.3.

Turn the ignition switch ON.

23.4.

Inspect for fuel leaks.

24. Program the transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.
25. Perform the idle learn procedure. Refer to Idle Learn .

Fuel Tank Replacement Left

Tools Required

Caution: 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.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
3. Drain the fuel tanks. Refer to Fuel Tank Draining .

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

•	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.
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the left rear tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Remove the left rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
7. Disconnect the fuel fill hose (1) and the vent pipe (2).



8. Remove the fuel tank shield mount nut (3).
9. Remove the fuel tank shield mount bolt (2).
10. Remove the fuel tank shield (1).
11. Remove the left muffler (auto trans equipped vehicles only). Refer to Muffler Replacement in Engine Exhaust.



12. Disconnect the fuel sender electrical connector.
13. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
14. Disconnect the auxiliary fuel return rear pipe (1) from the (1) jet pump to the left tank, the fuel return rear pipe (2), and the fuel feed rear pipe (3) at the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
15. Cap the fuel pipes in order to prevent possible fuel system contamination.



16. Disconnect the tank crossover hose (5).
17. Disconnect the EVAP pipe (2) quick-connect fitting at the left fuel tank EVAP pipe (1).
18. Cap the EVAP pipe in order to prevent possible contamination.



19. Remove the fuel tank strap mount bolts (1,2,4).
20. Remove the fuel tank strap (3).



21. Remove the fuel tank.

Important: Always replace the fuel system hose clamps with the original equipment or parts that meet the GM specifications for those parts when replacing the clamps.

1. Install the fuel tank.



2. Install the fuel tank strap (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the fuel tank strap bolts (1,2,4).

Tighten

1. Tighten bolt (2) to 25 N·m (18 lb ft).
2. Tighten bolt (1) to 25 N·m (18 lb ft).
3. Tighten the remaining bolts (4) to 25 N·m (18 lb ft).



4. Remove the cap from the EVAP pipe.
5. Connect the EVAP pipe (2) quick-connect fitting at the left fuel tank EVAP pipe (1).
6. Install the tank crossover hose (5).
7. Push the clamp outboard against the fuel tank keeping the clamp parallel with the white stripe on the tank crossover hose.

Tighten
Tighten the tank crossover hose clamp to 4 N·m (35 lb in).




8. Remove the caps from the fuel pipes.
9. Connect the auxiliary fuel return rear pipe (1) from the jet pump to the left tank, the fuel return rear pipe (2), and the fuel feed rear pipe (3) to the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
10. Connect the fuel sender electrical connector.
11. Install the left muffler (auto trans equipped vehicles only). Refer to Muffler Replacement in Engine Exhaust.



12. Install the fuel tank shield (1).
13. Install the fuel tank shield mount bolt (2).
14. Install the fuel tank shield mount nut (3).

Tighten

•	Tighten the fuel tank shield mount bolt to 25 N·m (18 lb ft).

•	Tighten the fuel tank shield mount nut to 12 N·m (106 lb in).




15. Connect the fuel fill hose (1) and the vent pipe (2).

Tighten
Tighten the fuel fill hose clamp to 3.5 N·m (31 lb in).

16. Install the left rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
17. Install the left rear tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
18. Lower the vehicle.
19. Refill the fuel system.
20. Connect the negative battery cable.
21. Inspect for leaks.

21.1.

Turn the ignition switch ON for 2 seconds.

21.2.

Turn the ignition switch OFF for 10 seconds.

21.3.

Turn the ignition switch ON.

21.4.

Inspect for fuel leaks.

22. Program the transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.
23. Perform the idle learn procedure. Refer to Idle Learn .