Fuel Tank Replacement (Right)

TOOLS REQUIRED
^ J 34730-1A Fuel Pressure Gauge
^ J 37088-A Tool Set, Fuel Line Quick Connect Separator

REMOVAL PROCEDURE

CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.




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

CAUTION: Refer to Vehicle Lifting Caution in Service Precautions.

4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the right rear fire and wheel.
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 for automatic transmission-equipped vehicles only.
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) that connects the jet pump to the left tank and the auxiliary fuel feed rear pipe (2) that connects the left tank to the jet pump at the fuel sender.
13. Cap the fuel pipes in order to prevent possible fuel system contamination.




14. Remove the right rear wheelhouse panel.
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).

Fuel Tanks:

23. Remove the fuel tank.

INSTALLATION PROCEDURE

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).

NOTE: Refer to the Fastener Notice in Service Precautions.

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

Tighten
3.1. Tighten the bolt (2) to 25 N.m (18 lb ft).
3.2. Tighten the bolt (1) to 25 N.m (18 lb ft).
3.3. 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.




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.
14. Connect the fuel sender electrical connector.




15. Install the right muffler, for automatic transmission- equipped vehicles only.
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 fire and wheel.
20. Lower the vehicle.
21. Refill the fuel system.
22. Connect the negative battery cable.
23. Perform the following procedure in order to 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 in Keyless Entry.