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Fuel Tank Replacement

Fuel Tank Replacement


Special Tools

EN-48279 Main Fuel Pump Locking Ring Remover/Installer

For equivalent regional tools, refer to Special Tools .

Removal Procedure


1. Open hood.

2.
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® (UE1) with Back Up Battery:

The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® 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® module in any way while the ignition is On or with RAP activated may cause activation of the OnStar® 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.


Turn the ignition OFF.

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

4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

6. Drain the fuel tank. Refer to Fuel Tank Draining .

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

8.
Warning

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


Disconnect the fuel tank filler vent pipe quick connector (1) from the fuel tank filler vent pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .


9. Remove the fuel tank filler hose fastener (3).

10. Remove the fuel tank filler hose (4).

11. Disconnect the evaporative emission front pipe quick connector from the evaporative emission front pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .


12. Disconnect the fuel feed front pipe quick connector from the fuel feed front pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .

13.
Note

Do NOT remove the rear axle.


Loosen both front fasteners of the rear axle. Lower the rear axle to 20 mm (0.8 in) . Refer to Rear Axle Replacement (G96) Rear Axle Replacement (Without G96) .

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

15. Remove both fuel tank strap fasteners (1).


16. Remove both fuel tank straps from the fuel tank (2).

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

18. Disconnect both fuel tank fuel pump module wiring harness connectors (1) from the fuel tank fuel pump modules.


19. Remove the fuel tank from the hydraulic lift.


Disassembly Procedure


1. Remove the fuel tank filler vent pipe (1) from the fuel tank.


2. Disconnect the fuel feed pipe (1) from the fuel tank and the fuel tank fuel pump module (2). Refer to Plastic Collar Quick Connect Fitting Service .


3. Disconnect the evaporative emission canister purge pipe (1) and the fuel tank vent pipe (2) from the evaporative emission canister (3). Remove the evaporative emission canister (3) from the fuel tank.


4.
Note

Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.


Install the EN-48279 remover/installer (1) to the fuel pump module lock ring (2).


5. Using the EN-48279 remover / installer and a long breaker-bar, rotate the fuel pump module lock rings (1) in a counterclockwise direction in order to unlock the fuel pump module lock rings.


6. Remove the fuel tank fuel pump modules (2).

7.
Note

Lift the fuel tank fuel pump modules up slightly.


Remove and discard the fuel tank fuel pump module O-ring seals (3).

8. Remove the 4 fuel tank shield fasteners (1).


9. Remove the fuel tank shield (2).


Assembly Procedure


1. Install the fuel tank shield (2).


2. Install the 4 fuel tank shield fasteners (1).

3. Install NEW fuel tank fuel pump module O-ring seals (3).


4. Install the fuel tank fuel pump modules (2).

5. Install the fuel pump module lock rings (1).

6.
Note

Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.


Using the EN-48279 remover/installer and a long breaker-bar, rotate the fuel pump module lock ring (1) in a clockwise direction in order to lock the fuel pump module lock ring (2).


7. Install the evaporative emission canister (3) to the fuel tank. Connect the evaporative emission canister purge pipe (1) and the fuel tank vent pipe (2) to the evaporative emission canister (3).


8. Connect the fuel feed pipe (1) to the fuel tank and the fuel tank fuel pump module (2). Refer to Plastic Collar Quick Connect Fitting Service .


9. Install the fuel tank filler vent pipe (1) to the fuel tank.



Installation Procedure


1. Refer to Fastener Caution .

Install the fuel tank to the hydraulic lift.


2. Connect the fuel tank fuel pump module wiring harness connectors (1) to the fuel tank fuel pump modules.

3. With the aid of an assistant, install the fuel tank to the vehicle.


4. Install both fuel tank straps to the fuel tank (2).

5. Install both fuel tank strap fasteners (1).

6. Remove the hydraulic lift from the fuel tank.

7. Install both front fasteners of the rear axle. Refer to Rear Axle Replacement (G96) Rear Axle Replacement (Without G96) .

8. Connect the fuel feed front pipe quick connector to the fuel feed front pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .


9. Connect the evaporative emission front pipe quick connector to the evaporative emission front pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .

10. Install the fuel tank filler hose (4).


11. Install the fuel tank filler hose fastener (3) and tighten to 4 Nm (35 lb in) .

12. Connect the fuel tank filler vent pipe quick connector (1) to the fuel tank filler vent pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .

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

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

15. Close hood.