GM Service Manual Online
For 1990-2009 cars only

Tools Required

J 37088-A Fuel Line Disconnect Tool

Removal Procedure

  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Remove the right rear wheelhouse panel. Refer to Rear Wheelhouse Panel Liner Replacement .
  4. Remove the driveline support assembly. Refer to Driveline Support Assembly Replacement .
  5. Remove the evaporative emission (EVAP) canister access cover.

  6. Object Number: 561895  Size: SH
  7. Disconnect the fill limit vent valve (FLVV) hose (1) at the EVAP canister (2).
  8. Disconnect the fuel pump module harness connector.
  9. Remove the crossover tube from the clamp located above the transmission.

  10. Object Number: 903539  Size: SH
  11. Disengage the crossover tube connector position assurance (CPA) retainer by pulling the tab (1) outward and rotate.
  12. Important: The crossover tube CPA is released when the latch disengages from the tank connection groove.


    Object Number: 903540  Size: SH
  13. Rotate crossover tube collar counterclockwise to disengage.

  14. Object Number: 903557  Size: SH
  15. Disconnect the crossover tube (5) from the right fuel tank by pulling the tube straight out of the fuel tank connection.

  16. Object Number: 903412  Size: SH

    Important: Take care not to disturb the internal O-rings in the fuel tank connections.

  17. Disconnect the EVAP crossover pipe (2) quick connect fitting at the right fuel tank.
  18. Cap the EVAP pipe to prevent system contamination.

  19. Object Number: 903428  Size: SH
  20. Remove the fuel tank strap mount bolts.
  21. Remove the fuel tank strap from the vehicle.

  22. Object Number: 903572  Size: SH
  23. Remove the fuel tank.

Installation Procedure


    Object Number: 903572  Size: SH
  1. Install the fuel tank.
  2. Install the fuel tank strap to the vehicle.

  3. Object Number: 903428  Size: SH
  4. Install the fuel tank strap bolts.
  5. Remove the cap from the EVAP pipe.

  6. Object Number: 903412  Size: SH
  7. Connect the EVAP crossover pipe (2) quick connect fitting at the right fuel tank.

  8. Object Number: 903547  Size: SH
  9. Lubricate the crossover tube to fuel tank connection O-rings (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.

  10. Object Number: 903557  Size: SH

    Important: Note the location of the T-shaped alignment feature (5) between the jet pump feed/return pipes connector.

  11. Lubricate the crossover tube O-ring mating surfaces (1-4) with GM P/N 1051717 (Canadian P/N 5728223) rubber lubricant.
  12. Important: 

       • Note the T-shaped alignment feature on the crossover tube.
       • The crossover tube will not fully seat into the fuel tank if the jet pump lines are misaligned.

  13. Connect the crossover tube to the right fuel tank using the features previously noted.
  14. Important: The crossover tube collar tangs will not latch if misalignment exists.

  15. Rotate the crossover tube collar (3) clockwise to engage the tangs.

  16. Object Number: 903539  Size: SH
  17. Rotate the crossover tube CPA retainer counterclockwise past the collar latching tang and push the tab (1) into the locked position.
  18. Important: If the CPA retainer is locked into position, the crossover tube collar will not rotate.

  19. Test the crossover tube to fuel tank connection by attempting to rotate the crossover tube collar counterclockwise.
  20. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 903428  Size: SH
  21. Tighten the fuel tank strap bolts.
  22. Tighten
    Tighten the bolts to 25 N·m (18 lb in).

  23. Snap the crossover tube into the clamp located above the transmission.
  24. Connect the fuel pump module harness connector.

  25. Object Number: 561895  Size: SH
  26. Connect the FLVV hose (1) at the EVAP canister (2).
  27. Install the EVAP canister access cover.
  28. Install the driveline support assembly. Refer to Driveline Support Assembly Replacement .
  29. Install the right rear wheelhouse panel. Refer to Rear Wheelhouse Panel Liner Replacement .
  30. Lower the vehicle.
  31. Refuel the fuel tank.
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  33. Perform the following procedure in order to test for leaks:
  34. 22.1. Turn ON the ignition switch for 2 seconds.
    22.2. Turn OFF the ignition for 10 seconds.
    22.3. Turn ON the ignition.
    22.4. Inspect for fuel leaks.
  35. Program the transmitters. Refer to Transmitter Programming .