GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section.

Caution: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.


    Object Number: 1636704  Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  2. Drain the fuel tank. Refer to Fuel Tank Draining.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  4. Disconnect the fuel tank vent pipe quick connect fittings (1, 4). Refer to Plastic Collar Quick Connect Fitting Service.
  5. Loosen the fuel fill pipe hose clamp (2) at the fuel tank.
  6. Remove the fuel fill pipe hose from the fuel tank.

  7. Object Number: 1636801  Size: SH
  8. Disconnect the fuel tank electrical connector (1) from the pass through connector.

  9. Object Number: 1631769  Size: SH
  10. Remove the exhaust pipe insulators from the underbody hangers.
  11. Remove the muffler insulators from the underbody hanger and slowly lower the exhaust in order to allow it to rest on the rear axle beam.

  12. Object Number: 1636706  Size: SH
  13. Place an adjustable jack under the fuel tank.
  14. Remove the fuel tank strap bolts.
  15. Remove the fuel tank straps.
  16. Using the adjustable jack, carefully lower the fuel tank away from the vehicle.
  17. With the aid of an assistant, place the fuel tank on a suitable work surface.

  18. Object Number: 1636693  Size: SH
  19. If replacing the fuel tank, perform the following steps. Remove the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service.

  20. Object Number: 1636696  Size: SH
  21. Remove the fuel feed intermediate pipe. Refer to Plastic Collar Quick Connect Fitting Service.

  22. Object Number: 1636697  Size: SH
  23. Remove the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service.

  24. Object Number: 1636804  Size: SH
  25. Disconnect and remove the fuel tank electrical harness.
  26. Remove the fuel tank module. Refer to Fuel Pump Module Replacement.

Installation Procedure


    Object Number: 1636804  Size: SH
  1. If the fuel tank was replaced, perform the following steps. Install the fuel tank module. Refer to Fuel Pump Module Replacement.
  2. Install and connect the fuel tank electrical harness.

  3. Object Number: 1636697  Size: SH
  4. Install the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service.

  5. Object Number: 1636696  Size: SH
  6. Install the fuel feed intermediate pipe. Refer to Plastic Collar Quick Connect Fitting Service.

  7. Object Number: 1636693  Size: SH
  8. Install the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service.

  9. Object Number: 1636706  Size: SH
  10. With the aid of an assistant, place the fuel tank on the suitable jack.
  11. Using the adjustable jack, carefully raise the fuel tank into position.
  12. Position the fuel tank straps.
  13. Caution: Refer to Fastener Caution in the Preface section.

  14. Install the fuel tank strap bolts.
  15. Tighten
    Tighten the bolts to 45 N·m (33 lb ft).

  16. Remove adjustable jack from under the fuel tank.

  17. Object Number: 1631769  Size: SH
  18. Raise the exhaust and install the muffler insulators to the underbody hangers.
  19. Install the exhaust pipe insulators to the underbody hangers.

  20. Object Number: 1636801  Size: SH
  21. Connect the fuel tank electrical connector (1) to the pass through connector.

  22. Object Number: 1636704  Size: SH
  23. Install the fuel fill pipe hose to the fuel tank.
  24. Tighten the fuel fill pipe hose clamp (2) at the fuel tank.
  25. Tighten
    Tighten the clamp to 4.5 N·m (40 lb in).

  26. Connect the fuel tank vent pipe quick connect fittings (1, 4). Refer to Plastic Collar Quick Connect Fitting Service.
  27. Lower the vehicle.
  28. Refill the fuel tank.
  29. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  30. Inspect for fuel leaks using the following procedure:
  31. 20.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    20.2. Turn OFF the ignition for 10 seconds.
    20.3. Turn ON the ignition, with the engine OFF.
    20.4. Inspect for fuel leaks.