GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

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.


    Object Number: 17069  Size: SH
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
  3. Drain the fuel tank. Refer to Draining Fuel Tank.
  4. Remove the filler door bezel attaching screws and the filler door bezel.
  5. Remove the fuel filler cap (2).
  6. Lift the fuel tank filler pipe housing (1) and disconnect the drain hose (4) from the nipple (3).
  7. Reinstall the fuel filler cap in order to prevent dirt and debris from entering the fuel tank.
  8. Remove the fuel tank filler pipe housing (1).
  9. Disconnect the fuel sender assembly electrical connector.
  10. Clean all the fuel connections and the surrounding areas before disconnecting the hoses in order to avoid possible contamination of the fuel system.
  11. Disconnect the fuel feed hose, the fuel return hose, and the EVAP hose from the fuel sender assembly.
  12. Remove the license plate and bracket to gain access for removal of the carriage bolts.
  13. Remove the backup lamp assemblies.
  14. Remove the inner stop lamp assemblies.
  15. Disconnect the outer stop lamp electrical connectors.
  16. Remove the high mount stop lamp socket.
  17. Remove the carriage bolts securing the fascia to the impact bar.
  18. Remove the upper rear fascia to the upper rear body panel bolts.
  19. Raise the vehicle on a hoist.
  20. Remove the spare tire and the tire carrier from the frame.
  21. Remove the underbody braces (convertible only).
  22. With the aid of an assistant, remove the exhaust system as an assembly from the rear of the converters.
  23. Remove the EVAP canister splash shield.
  24. Remove the lower body panel supports.
  25. Remove the wheelhouse liner panels.
  26. Disconnect the EVAP pipes from the EVAP canister.
  27. Remove the EVAP canister.
  28. Disconnect the fuel tank cables from the stabilizer shaft supports.
  29. Remove the attaching screws securing the bottom edge of the fascia to the energy absorber bracket.
  30. Remove the marker lamps.
  31. Remove the attaching nuts securing each side of the vertical outer retainer to the fascia.
  32. Remove the power antenna assembly from the mounting bracket.
  33. Remove the rear fascia.
  34. Remove the rear impact bar bolts.
  35. Loosen the front impact bar bolts.
  36. With the aid of an assistant, support the impact bar and remove the front impact bar bolts.
  37. Remove the impact bar and the fuel tank assembly.
  38. Remove the fuel tank straps from the fuel tank and the impact bar.
  39. Remove the fuel tank from the impact bar.

  40. Object Number: 13644  Size: SH
  41. Remove the fuel tank cables (1) from the stabilizer shaft support bracket bolts (2).
  42. Remove the EVAP connections and the hose.
  43. Remove the fuel sender assembly.

Installation Procedure


    Object Number: 13644  Size: SH
  1. Install the fuel sender assembly.
  2. Install the EVAP connections and the hoses.
  3. Install the fuel tank cables (1) to the stabilizer shaft support bracket bolts (2).
  4. Install the fuel tank to the impact bar.
  5. Install the fuel tank straps to the fuel tank and the impact bar.
  6. Tighten

        • Tighten the fuel tank strap bolts to 14.5 N·m (11 lb ft).
        • Tighten the fuel tank strap nuts to 4.5 N·m (40 lb in).

    Object Number: 17069  Size: SH
  7. With the aid of an assistant, install the impact bar and the fuel tank assembly.
  8. Install all the impact bar bolts.
  9. Tighten
    Tighten the impact bar bolts to 50 N·m (37 lb ft).

  10. Install the rear fascia.
  11. Install the nuts to the vertical outer fascia retainers securing fascia to the body.
  12. Tighten
    Tighten the outer fascia retainer nuts to 6 N·m (53 lb in).

  13. Install the power antenna assembly to the mounting bracket.
  14. Install the nuts to each side of the fascia to the fascia horizontal retainer.
  15. Tighten
    Tighten the fascia retainer nuts to 6 N·m (53 lb in).

  16. Install the marker lamps.
  17. Install the screws securing the bottom edge of the fascia to the energy absorber bracket.
  18. Install the fuel tank cables to the stabilizer shaft supports.

    Tighten
    Tighten the fuel tank cable nuts to 25 N·m (18 lb ft).

  19. Install the EVAP canister.
  20. Connect the hoses to the EVAP canister.
  21. Install both rear wheelhouse liner panels.
  22. Install the lower body panel supports.
  23. Install the canister splash shield.
  24. With the aid of an assistant, install the exhaust system as an assembly.
  25. Install the underbody braces (convertible only).
  26. Tighten

        • Tighten the underbody brace nuts to 27 N·m (20 lb ft).
        • Tighten the underbody brace bolts to 62.5 N·m (46 lb ft).
  27. Install the spare tire carrier and the spare tire to the frame.
  28. Lower the vehicle.
  29. Install the bolts securing the upper rear fascia to the upper rear body panel.
  30. Install the carriage bolts securing the fascia to the impact bar.
  31. Install the high mount stop lamp socket.
  32. Install the outer stop lamp electrical connectors.
  33. Install the inner stop lamp assemblies.
  34. Install the backup lamp assemblies.
  35. Install the license plate bracket and the license plate.
  36. Connect the fuel feed hose (10), the fuel return hose (5), and the EVAP hose (6) to the fuel sender.
  37. Connect the fuel sender electrical connector.
  38. Connect the drain hose (4) and install the fuel tank filler pipe housing (1).
  39. Refill the fuel tank.
  40. Install the fuel filler cap (2).
  41. Connect the negative battery cable.
  42. Inspect for leaks.
  43. 37.1. Turn the ignition switch ON for 2 seconds.
    37.2. Turn the ignition switch OFF for 10 seconds.
    37.3. Turn the ignition switch ON.
    37.4. Check for fuel leaks.
  44. Install the fuel filler door bezel.