Removing
1. Open the hood.
Attention.
- Unless otherwise specified, the ignition switch must be in the OFF or LOCK position and all electrical appliances must be turned off before servicing any electrical components. Disconnect the negative battery terminal to prevent sparking when a tool or equipment touches exposed electrical leads. Failure to follow these instructions may result in personal injury and/or damage to the vehicle or its components.
- Owners of vehicles equipped with OnStar® (UE1) with backup battery:
- The backup battery is an alternative power source with some limitations in functionality in the event of a failure of the main battery. Do not disconnect the main battery or remove the OnStar® fuse when the ignition switch is in any position other than OFF. Temporary power function for accessories (RAP) must be deactivated by time or disabled (by simply opening the driver's door) before disconnecting the power. Losing power to the OnStar® module, either with the ignition on or with the RAP feature enabled, can cause the OnStar® system backup battery to activate, potentially draining the backup battery and even damaging it. If the backup battery is activated, it will be connected until it is completely discharged. The backup battery is not rechargeable and must be replaced with a new one after use.
2. Turn off the ignition.
3. Disconnect the negative battery terminal.
4. Relieve pressure in the fuel system.
5. Raise and secure the vehicle.
6. Remove fuel from the tank.
7. Remove the exhaust pipe.
Attention. Do not blow through lines or hoses in the evaporative emission system. Fuel vapors inside system components can cause poisoning.
8. Disconnect the quick connector (1) from the vent pipe of the filler neck (2).
9. Remove mount (3) fuel tank filler hose.
10. Remove the inlet hose (4) fuel tank.
11. Disconnect the quick connector from the front pipe of the evaporative emission system (1).
12. Disconnect the quick connector from the front pressure fuel line (2).
13. Place a suitable hydraulic jack under the fuel tank.
14. Unscrew the fastening bolts (1) and remove clamps (2) fuel tank.
15. With the help of an assistant, lower the hydraulic jack to remove the fuel tank from the vehicle.
16. Disconnect connector (1) fuel pump wiring harness.
17. Remove the fuel tank from the hydraulic jack.
Disassembly
1. Remove the ventilation pipe (1) from the fuel tank.
2. Disconnect the pressure fuel line (1) from fuel tank and fuel pump module (2).
3. Disconnect the fuel tank vent (1) from the carbon filter (2) fuel vapor recovery systems. Remove charcoal filter (2) from the fuel tank.
4. Install fixture EN-48279 (1) on the fixing ring of the fuel pump module (2).
Note. Do not use a pulse driven tool. Significant force is required to loosen the retaining ring. The use of a hammer and screwdriver is also not recommended. Secure the fuel tank to prevent the fuel tank from tipping over.
5. Using tool EN-48279 and a long pry bar, turn the retaining ring (1) fuel pump module counterclockwise to unlock the fuel pump module.
6. Remove the fuel pump module (2).
Note. Remove the fuel pump module from the tank smoothly.
7. Remove and dispose of O-ring (3) fuel pump module.
8. Loosen fasteners (1) fuel tank protection.
9. Remove the fuel tank protection (1).
Assembly
1. Install the fuel tank guard.
2. Install the fuel tank guard fasteners.
3. Install a new O-ring (3) fuel pump module.
4. Install the fuel pump module (2) and fixing ring (1).
Note. Do not use a pulse driven tool. Significant force is required to loosen the retaining ring. The use of a hammer and screwdriver is also not recommended. Secure the fuel tank to prevent the fuel tank from tipping over.
5. Using tool EN-48279 and a long pry bar, turn the retaining ring (1) fuel pump module clockwise to lock the fuel pump module.
6. Connect the ventilation pipe (1) fuel tank to the carbon filter of the fuel vapor recovery system (2), then install the carbon filter on the fuel tank.
7. Connect the pressure fuel line (1) to fuel tank and fuel pump module (2).
8. Install the ventilation pipe (1) filler neck on the fuel tank.
Installation
1. Install the fuel tank on a hydraulic jack.
2. Connect connector (1) fuel pump module wiring harness.
3. With the help of an assistant, install the fuel tank on the vehicle.
4. Install fuel tank clamps (2) and tighten the mounting bolts (1).
5. Remove the hydraulic jack from under the fuel tank.
6. Connect the quick connector of the front pressure fuel line (2).
7. Connect quick connector (1) front pipe of the fuel vapor recovery system.
8. Install the filling hose (4) to the fuel tank.
9. Install clamp (3) on the filling hose and tighten to 4 Nm.
10. Connect quick connector (1) ventilation pipe of the fuel tank filling neck.
11. Install the exhaust system.
12. Connect the negative battery terminal.
13. Close the hood.
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