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Home >> Chevrolet >> 2011 >> HHR LS, Standard >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 2.2L Or 2.4L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure

Removal Procedure

WARNING:

Refer to Gasoline/Gasoline Vapors Warning .

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.

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) , Fuel Pressure Relief (CH 48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining (Non E-85) , Fuel Tank Draining (E-85) .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    4. Fig 1: Fuel Tank Vent Pipe Quick Connect Fittings, Hose And Clamp
    GM2442966Courtesy of GENERAL MOTORS COMPANY
  4. Disconnect the fuel tank vent pipe quick connect fitting (1) from the evaporative emission canister. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Disconnect the fuel tank vent pipe quick connect fitting (2) from the fill tube vent pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Loosen the fuel fill pipe hose clamp (3) and remove the hose (4) from the fuel tank.
    7. Fig 2: Fuel Tank Electrical Connector
    GM2442991Courtesy of GENERAL MOTORS COMPANY
  7. Disconnect the fuel tank electrical connector (1) from the pass through connector.
    8. Fig 3: Exhaust Pipe Insulators
    GM2442984Courtesy of GENERAL MOTORS COMPANY
  8. Remove the exhaust pipe insulators (1) from the underbody hangers.
    9. Fig 4: Muffler Insulators
    GM2442978Courtesy of GENERAL MOTORS COMPANY
  9. Remove the muffler insulators (1) from the underbody hanger and slowly lower the exhaust in order to allow it to rest on the rear axle beam.
  10. Place an adjustable jack under the fuel tank.
    11. Fig 5: Fuel Tank Straps And Bolts
    GM2442975Courtesy of GENERAL MOTORS COMPANY
  11. Remove the fuel tank strap bolts (1) and the fuel tank straps (2).
  12. Carefully lower the fuel tank away from the vehicle.
  13. With the aid of an assistant, place the fuel tank on a suitable work surface.
    14. Fig 6: Fuel Tank Module, Vent Pipes, Fuel Feed Intermediate Pipe And Electrical Harness
    GM2442971Courtesy of GENERAL MOTORS COMPANY
  14. If replacing the fuel tank, perform the following steps. Remove the fuel tank vent pipes (3, 5). Refer to Plastic Collar Quick Connect Fitting Service .
  15. Remove the fuel feed intermediate pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
  16. Disconnect and remove the fuel tank electrical harness (1).
  17. Remove the fuel tank module (4). Refer to Fuel Pump Module Replacement .
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