Fuel Tank Replacement Right w/Auto Trans

Removal Procedure

Tools Required

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

•	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.

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 .
4. Raise the vehicle.
5. Remove the right rear tire and wheel.
6. Remove the right muffler. Refer to Muffler Replacement in Engine Exhaust.
7. Disconnect the fuel sender electrical connector.
8. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
9. Disconnect the fuel sender fuel feed pipe (1) (jet pump to left tank) and the fuel feed rear crossover pipe (2) (left tank to jet pump) at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
10. Cap the fuel pipes in order to prevent possible fuel system contamination.



11. Disconnect the tank crossover hose (3).

Important: Do not disconnect the EVAP hose at the fuel tank roll over valve.

12. Carefully disconnect the EVAP hose at the T-connector (2).



13. Remove the fuel tank strap/shield (4).
14. 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/shield (4).

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/shield bolts.

3.1.	Install the net hole bolt (3).

3.2.	Install the slot location bolt (1).

3.3.	Install the remaining bolts (2 and 5).

Tighten
Tighten the fuel tank strap/shield bolts to 25.5 N·m (19 lb ft).




4. Connect the EVAP hose at the T-connector (2).
5. Connect the tank crossover hose (3).
6. 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).




7. Remove the caps from the fuel pipes.
8. Connect the fuel sender fuel feed pipe (1) (jet pump to left tank) and the fuel feed rear crossover pipe (2) (left tank to jet pump). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
9. Connect the fuel sender electrical connector.
10. Install the right muffler. Refer to Muffler Replacement in Engine Exhaust.
11. Install the right rear tire and wheel.
12. Lower the vehicle.
13. Refill the fuel system.
14. Connect the negative battery cable.
15. Inspect for leaks.

15.1.

Turn the ignition switch ON for 2 seconds.

15.2.

Turn the ignition switch OFF for 10 seconds.

15.3.

Turn the ignition switch ON.

15.4.

Check for fuel leaks.

16. Perform the idle learn procedure. Refer to Idle Learn .

Fuel Tank Replacement Left w/Auto Trans

Removal Procedure

Tools Required

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

•	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.

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 .
4. Raise the vehicle.
5. Remove the left rear tire and wheel.
6. Remove the left muffler. Refer to Muffler Replacement in Engine Exhaust.
7. Remove the left rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
8. Disconnect the fuel fill hose (3) and the vent hose (4).



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



13. Disconnect the tank crossover hose (3).

Important: Do not disconnect the EVAP hose at the roll over valve.

14. Carefully disconnect the EVAP hose at the T-connector (1).



15. Remove the fuel tank strap/shield (4).
16. 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/shield (4).

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/shield bolts.

3.1.	Install the net hole location bolt (3).

3.2.	Install the slot location bolt (1).

3.3.	Install the remaining bolts (2 and 5).

Tighten
Tighten the fuel tank strap/shield bolts to 25.5 N·m (19 lb ft).




4. Connect the EVAP hose at the T-connector (1).
5. Install the tank crossover hose (3).
6. 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).




7. Remove the caps from the fuel pipes.
8. Connect the fuel sender fuel feed pipe (1) (jet pump to left tank), the fuel return rear pipe (2), and the fuel feed rear pipe (3). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
9. Connect the fuel sender electrical connector.



10. Connect the fuel fill hose (3) and the vent hose (4).

Tighten
Tighten the fuel fill hose clamp and the vent hose clamp to 4 N·m (35 lb in).

11. Install the left rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
12. Install the left muffler. Refer to Muffler Replacement in Engine Exhaust.
13. Install the left rear tire and wheel.
14. Lower the vehicle.
15. Refill the fuel system.
16. Connect the negative battery cable.
17. Inspect for leaks.

17.1.

Turn the ignition switch ON for 2 seconds.

17.2.

Turn the ignition switch OFF for 10 seconds.

17.3.

Turn the ignition switch ON.

17.4.

Check for fuel leaks.

18. Perform the idle learn procedure. Refer to Idle Learn .

Fuel Tank Replacement Right w/Manual Trans

Removal Procedure

Tools Required

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

•	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.

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 .
4. Raise the vehicle.
5. Remove the right rear tire and wheel.
6. Disconnect the fuel sender electrical connector.
7. Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.
8. Disconnect the fuel sender fuel feed pipe (1) (jet pump to left tank) and the fuel feed rear crossover pipe (2) (left tank to jet pump) at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
9. Cap the fuel pipes in order to prevent possible fuel system contamination.



10. Disconnect the tank crossover hose (3).

Important: Do not disconnect the EVAP hose at the roll over valve.

11. Carefully disconnect the EVAP hose at the T-connector (2).



12. Remove the fuel tank strap/shield (4).
13. 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/shield (4).

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/shield bolts.

3.1.	Install the net hole bolt (3).

3.2.	Install the slot location bolt (1).

3.3.	Install the remaining bolts (2 and 5).

Tighten
Tighten the fuel tank strap/shield bolts to 25.5 N·m (19 lb ft).




4. Connect the EVAP hose at the T-connector (2).
5. Connect the tank crossover hose (3).
6. 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).




7. Remove the caps from the fuel pipes.
8. Connect the fuel sender fuel feed pipe (1) (jet pump to left tank) and the fuel feed rear crossover pipe (2) (left tank to jet pump). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
9. Connect the fuel sender electrical connector.
10. Install the right rear tire and wheel.
11. Lower the vehicle.
12. Refill the fuel system.
13. Connect the negative battery cable.
14. Inspect for leaks.

14.1.

Turn the ignition switch ON for 2 seconds.

14.2.

Turn the ignition switch OFF for 10 seconds.

14.3.

Turn the ignition switch ON.

14.4.

Check for fuel leaks.

15. Perform the idle learn procedure. Refer to Idle Learn .

Fuel Tank Replacement Left w/Manual Trans

Removal Procedure

Tools Required

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

•	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.

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 .
4. Raise the vehicle.
5. Remove the left rear tire and wheel.
6. Remove the left rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
7. Disconnect the fuel fill hose (3) and the vent hose (4).



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



12. Disconnect the tank crossover hose (3).

Important: Do not disconnect the EVAP hose at the roll over valve.

13. Carefully disconnect the EVAP hose at the T-connector (1).



14. Remove the fuel tank strap/shield (4).
15. 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/shield (4).

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/shield bolts.

3.1.	Install the net hole location bolt (3).

3.2.	Install the slot location bolt (1).

3.3.	Install the remaining bolts (2 and 5).

Tighten
Tighten the fuel tank strap/shield bolts to 25.5 N·m (19 lb ft).




4. Connect the EVAP hose at the T-connector (1).
5. Connect the tank crossover hose (3).
6. 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).




7. Remove the caps from the fuel pipes.
8. Connect the fuel sender fuel feed pipe (1) (jet pump to left tank), the fuel return rear pipe (2), and the fuel feed rear pipe (3). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
9. Connect the fuel sender electrical connector.



10. Connect the fuel fill hose (3) and the vent hose (4).

Tighten
Tighten the fuel fill hose clamp and the vent hose clamp to 4 N·m (35 lb in).

11. Install the left rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
12. Lower the vehicle.
13. Install the left rear tire and wheel.
14. Refill the fuel system.
15. Connect the negative battery cable.
16. Inspect for leaks.

16.1.

Turn the ignition switch ON for 2 seconds.

16.2.

Turn the ignition switch OFF for 10 seconds.

16.3.

Turn the ignition switch ON.

16.4.

Check for fuel leaks.

17. Perform the idle learn procedure. Refer to Idle Learn .